GSi Cumberland Hi-Lo Installation And Operation Manual Download

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PNEG-250

Hi-Lo and PRO-1 Pan Feeders

(For parts, refer to PNEG-250-PM)

Installation and Operation Manual

PNEG-250

Date: 05-19-14

Summary of Contents for Cumberland Hi-Lo

Page 1: ...PNEG 250 Hi Lo and PRO 1 Pan Feeders For parts refer to PNEG 250 PM Installation and Operation Manual PNEG 250 Date 05 19 14...

Page 2: ...2 PNEG 250 Hi Lo and PRO 1 Pan Feeders...

Page 3: ...Anti Roost Wire 67 Hopper Level Control Switch 69 Winching 70 Power Winch Instructions 77 Chapter 8 Troubleshooting 83 Chapter 9 Wiring Diagrams 85 Rooster Power Winch Wiring Diagram 85 Microswitch En...

Page 4: ...e house floor and presents a lip height of 2 1 5 334 cm the average height of traditional feeder lids Young chicks can easily get in and out of the pan and are eating out of the pan from day one And b...

Page 5: ...s 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...

Page 6: ...stallations are made 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...

Page 7: ...uilding s load capacity Likely estimated weights of the Pan Feeding System are provided in the table in the Installation Manual Correct Use of the Pan Feeder System The Pan Feeder System is designed s...

Page 8: ...n in the maintenance section of this manual Before restarting the Pan Feeder System ensure that all electrical enclosures are locked closed and all guards and other safety measures are correctly fitte...

Page 9: ...TION in working around the Pan Feeding System s moving parts This product is intended for the use of feed handling only Any other use is considered a misuse of the product Some edges of the product s...

Page 10: ...perating and safety procedures for this auger This sign off sheet is provided for your convenience and personal record keeping All unqualified persons are to stay out of the work area at all times It...

Page 11: ...operator of potential injury or death from electrical shock DC 889 The decal shown is located on the lid of the Hi Lo control pan It measures 2 8 wide x 1 4 tall It alerts the operator of injury or de...

Page 12: ...ck out the power before servicing GSI Group Inc 217 226 4421 ROTATING AUGER Keep clear of moving parts Will cause serious injury Disconnect and lockout power before servicing DC 993 WARNING DC 884 The...

Page 13: ...operator to disconnect and lock out the power before servicing The above pictures show the drive mount with the lid off for illustration purposes only Never operate the system without the lid in plac...

Page 14: ...ty weight PC using the Capacities and Specifications Section on Pages 15 and 16 Add these two 2 weights together and multiply by the number of pans per tube section NP to get the total pan weight TPW...

Page 15: ...190 380 208 230 460 50 or 60 Direct Drive 358 28 4 lbs 12 9 kgs Model Diameter Weight Hi Lo 13 330 mm 1 6 lbs 0 7 kgs PRO 1 13 330 mm 1 8 lbs 0 8 kgs Capacity Height Top Opening Weight 120 lbs 54 kgs...

Page 16: ...Hi Lo Spinner 8 8 lbs 4 0 kgs Hi Lo Proximity 3 7 lbs 1 6 kgs Length Weight Feed Hole Tubes Feed and Brood Hole Tubes 9 ft 2 74 m 7 5 lbs 3 4 kgs 0 1 2 4 8 Centered Staggared 4 or 6 10 ft 3 05 m 8 3 l...

Page 17: ...It is not recommended that a drive unit ever be located more than 500 from the hopper boot Figure 6A shows a single boot feed system with the feed tank at the end of the house Figure 6A Single Boot Fe...

Page 18: ...rs House Layout Continued Figure 6B shows a double boot feed system with the feed tank in the middle of the house Figure 6B Double Boot Feed System Ref Description A Drive Unit Control Pan B Tubing C...

Page 19: ...eeders with two piece drop tubes may be assembled before or after the tubes are assembled Hi Lo Feeder Assembly One Piece Drop Tube 1 Place the grill on the drop tube A as shown in Figure 7A Figure 7A...

Page 20: ...ver the hole opening on the tube See Figure 7C Figure 7C Figure 7D 2 Push the grill up on to the top piece of the two piece drop tube See Figure 7D 3 Slide the bottom piece of the two piece drop tube...

Page 21: ...If the indicator bumps B are not aligned remove the bottom and turn it 180 Proper alignment can also be found by following the text on the top and bottom drop tube pieces IMPORTANT Top and bottom pie...

Page 22: ...If the clip becomes fixed while out of a notch the feed flow may stop It will be difficult to return the clip to a slot if it becomes fixed while out of a slot Optimal results will be obtained by main...

Page 23: ...n on the assembly See Figure 7K Figure 7K 10 The completed assembly should look like the image below See Figure 7L NOTE Disassembly of the pan and grill may be performed by lifting on one side of the...

Page 24: ...e clear window guard C over lower drop tube Figure 7M Figure 7N 3 Align slot on locking collar F with tab on lower drop tube D and slide over the lower drop tube See Figure 7O 4 Insert the drop tube a...

Page 25: ...ion which prevents the pan from collapsing or in a collapsed position to take advantage of the Hi Lo feature Uncollapsed Pan Lift locking collar C2000212 and use the tabs on both the locking collar an...

Page 26: ...the locking collar in its assembled or lowered position to allow the pan to collapse into the grill for standard Hi Lo operation as shown in Figure 7U When the feed line is lowered to ground level th...

Page 27: ...2000209 lower drop tube C2000210 feed level adjustor C2000211 and the locking collar C2000212 Simply remove the existing Hi Lo feed level stand 7098855 and Hi Lo feed level 7098854 and follow the inst...

Page 28: ...1 Pan Feeders 2 Align the arrow on the drop tube assembly D with the letter E on the grill C and then lower the grill onto the drop tube See Figure 7X of drop tube alignment with the arrow A aligned w...

Page 29: ...Assemble the pan to the grill by placing the pan hook over the grill bar to act as a hinge See Figure 7Y Figure 7Y 4 Pivot the pan up until it is seated into the bottom of the grill and then rotate t...

Page 30: ...Pan Feeders 5 To install the drop tube a For one piece drop tube Slide the drop tube onto the auger tube b For two piece drop tube Snap the drop tube onto the auger tube and slide the drop tube cap on...

Page 31: ...u MUST lift the grill out of the locking grooves D and rotate and align the arrow indicator on the feed level skirt with D E or F on the grill E Then lower the grill back into the locked position F Se...

Page 32: ...gth of the building starting with the bell end towards the boot C See Figure 7AC and Figure 7AD Figure 7AC Figure 7AD Ref Description A Boot B 1 3 4 Insulator Bracket Assembly C Belled End of Tube Ref...

Page 33: ...acing the control unit end Do not attach tube clamps at this time 1 Starting with the poultry boot attach a double swedged tube A to each outlet on the boot If single boot D use one if double boot E u...

Page 34: ...Use the Programming Charts on Pages 41 46 to determine which notch in the anti rotation clip each tube rib will be inserted into Charts are listed according to tube length and RPM 4 When standing at...

Page 35: ...d to See Figure 7AL and Figure 7AM Figure 7AL Anti Rotation Clip Open Figure 7AM Anti Rotation Clip Snapped Together 6 Attach and secure tube clamps where tubes come together 7 Attach the scissor hang...

Page 36: ...ece Drop Tube 1 Place the top of the two piece drop tube over the hole opening on the tube See Figure 7AN Figure 7AN 2 Push the grill up on to the assembly See Figure 7AO and Figure 7AP Figure 7AO Fig...

Page 37: ...t be aligned See Figure 7AT Failure to do so will result in feed sifting where the drop tube meets the tube If these are not aligned remove the bottom and turn it 180 If a SHUT OFF SLIDE IS USED indic...

Page 38: ...ssembly and pull the two 2 pieces apart See Figure 7AV Figure 7AV 8 Slide the telescoping restrictor over the smaller funnel restrictor with the legs pointed down See Figure 7AW Figure 7AW 9 Place the...

Page 39: ...t the feed flow can stop It will be difficult to return the clip G to a slot if it becomes fixed while out of a slot Optimum results will be obtained by maintaining as shallow of feed depth as possibl...

Page 40: ...e side of the pan while pushing down on the other side and flexing the grill With practice this operation will become easy for cleaning Place the pan on the assembly See Figure 7BC Figure 7BC 14 Slide...

Page 41: ...Hi Lo and PRO 1 Pan Feeders 41 Program Chart Figure 7BF Anti rotation clip orientation when viewed from the hopper toward the drive unit Home plate with point facing down Tube Qty Programming Chart 9...

Page 42: ...PNEG 250 Hi Lo and PRO 1 Pan Feeders Figure 7BG Anti rotation clip orientation when viewed from the hopper toward the drive unit Home plate with point facing down Tube Qty Programming Chart Tube 9 Au...

Page 43: ...EG 250 Hi Lo and PRO 1 Pan Feeders 43 Figure 7BH Anti rotation clip orientation when viewed from the hopper toward the drive unit Home plate with point facing down Tube Qty Programming Chart 10 Auger...

Page 44: ...PNEG 250 Hi Lo and PRO 1 Pan Feeders Figure 7BI Anti rotation clip orientation when viewed from the hopper toward the drive unit Home plate with point facing down Tube Qty Programming Chart Tube 10 A...

Page 45: ...EG 250 Hi Lo and PRO 1 Pan Feeders 45 Figure 7BJ Anti rotation clip orientation when viewed from the hopper toward the drive unit Home plate with point facing down Tube Qty Programming Chart 12 Auger...

Page 46: ...PNEG 250 Hi Lo and PRO 1 Pan Feeders Figure 7BK Anti rotation clip orientation when viewed from the hopper toward the drive unit Home plate with point facing down Programming Chart 12 Auger Tube 716...

Page 47: ...unt See Figure 7BM or anchor plate See Figure 7BN depending on the model of the control pan to the gearbox of the drive unit See Figure 7BL using the four 4 bolts provided with the control unit Figure...

Page 48: ...a Take off drop tube b Place through grill c Replace drop tube onto control pan base d Assemble remainder of Hi Lo pan components Figure 7BP 5 On the Hi Lo microswitch control pan attach slope panel u...

Page 49: ...ottom covers See Figure 7BU Figure 7BT Figure 7BU 10 Remove the vent plug F at the top of the gearbox See Figure 7BV on Page 50 11 Fill the gearbox with the recommended quantity of lubricant found on...

Page 50: ...be mounted between two 2 sections of auger tube by trimming one auger bell as shown in Figure 7BX on Page 51 and installing it as shown in Figure 7BY on Page 51 with two 2 1 3 4 U bolts included Depe...

Page 51: ...7 Installation PNEG 250 Hi Lo and PRO 1 Pan Feeders 51 Figure 7BX Figure 7BY...

Page 52: ...pan and two 2 holes in front of the center house pan must be enlarged 2 Begin by enlarging the feed hole in the auger tube Use a hacksaw and tin snips to cut out material as shown in Figure 7BZ Make...

Page 53: ...Feeders 53 Adjusting the Hi Lo Microswitch Control Pans End and Center House 1 Check switch and adjust if necessary Switch should click with 1 4 of movement See Figure 7CC Figure 7CC 2 Assemble remai...

Page 54: ...a sight glass The worst case condition exists when moisture is present on the inside surface of the glass Turn the potentiometer clockwise CW until the LED is OFF then turn the potentiometer countercl...

Page 55: ...at of the end control and center house control pans See Figure 7CG Should any part need replaced the PC board has two 2 diagnostic lights green and yellow to help determine the status of the component...

Page 56: ...tem without the lid in place Never remove the lid without first disconnecting and locking out the power The Cumberland Hi Lo control pan features a starting pulse on the spinning sensor motor in the c...

Page 57: ...ox See Figure 7CK Figure 7CL below and Figure 7CM on Page 58 for connections 5 In the center house control pan D switch box connect the wire that you just ran to the leads coming into the back of the...

Page 58: ...to 20 gauge blue and 20 gauge yellow to 20 gauge red See Figure 7CM Figure 7CM End Control Pan 8 In the switch box assembly connect the wire from the center house control pan to the leads from the sw...

Page 59: ...e switch Figure 7CO 10 Connect the black lead to the remaining terminal on the switch and tie the red lead together with the other red and blue leads See Figure 7CP Figure 7CP Ref Description Ref Desc...

Page 60: ...straighten by hand use locking pliers If the auger still cannot be straightened cut it on both sides of the bend and remove the bent portion A hacksaw or bolt cutters can be used to cut the auger Refe...

Page 61: ...the boot 10 Mark the auger at the point which allows the proper stretch C See Figure 7CS Figure 7CS Use caution when releasing the tension on the auger If the auger moves too quickly in any direction...

Page 62: ...overtighten the U clamp or distortion of the auger tube may result Rapid cooling will cause hardening and embrittlement The auger must be smooth to prevent feed build up and premature tube wear 13 Cut...

Page 63: ...mm to 19 mm 21 Use a bronze flux coated rod and low heat as overheating could warp the auger 22 To keep the auger aligned and to prevent warping and kinking lay the auger into an angle or channel iro...

Page 64: ...onto the top of the boot 4 Secure the hopper to the boot by inserting the pin B from the boot through the holes in the hopper bottom flange and boot top flange as shown in Figure 7CX 5 Feed agitation...

Page 65: ...r scale assembly at the desired height 3 Assemble the hopper hangers B to the hopper A during hopper assembly The hangers for 120 200 lbs hoppers and 300 400 lbs hoppers are included with the scale Us...

Page 66: ...CONTROL UNIT JUMPER ADDED IN FIELD HOPPER LEVEL SWITCH NOT USED WHITE BLACK GREEN MOM SWITCH 230V FEMALE PLUG FROM CONTROL UNIT 230V MALE PLUG FROM SCALE SWITCH BOX 230V MALE MOTOR PLUG 230V FEMALE PL...

Page 67: ...igure 7DA 2 Secure the anti roost wire around the insulator A with the cable clamp sleeves C provided as shown in Figure 7DA Figure 7DA 3 Thread the anti roost cable through the slots in the tops of t...

Page 68: ...n Figure 7DC Figure 7DC There should be 3 4 to 1 1 cm to 2 5 cm of stretch on the spring 6 Cut the cable with enough slack to loop D the end of the cable through the spring and secure it with a cable...

Page 69: ...r When installed the switch must hang vertically or at a slight angle so that gravity will cause the switch paddle to activate and close the operating circuit Bend the mounting bracket as necessary to...

Page 70: ...when Raising and Lowering The main risk when raising and lowering the feed line is that a cable may snap or slip This may result in cable whip or the feed line falling Therefore the use of a hard hat...

Page 71: ...oppers bolt two 2 halves of the hopper suspension brackets together with four 4 support brackets D using twelve 12 5 16 18 bolts and nuts See Figure 7DH The drop cables will need to be spaced 19 apart...

Page 72: ...apart for 120 and 200 hoppers or 25 for 300 and 400 hoppers Suspend the boot using the two 2 drops on each side of the hopper as shown in Figure 7DI Bolt the cable guides to two 2 sides of the hopper...

Page 73: ...rland representative 4 Ensure that the openings of the screw hooks point away from the direction of cable travel E when the winch raises the feeder as shown in Figure 7DK If the distance raised is gre...

Page 74: ...or some type of fastener The winch cable does not pass though any pulleys See Figure 7DL 8 For systems longer than 360 109 7 m install the cable with double reduction pulleys as shown in Figure 7DM F...

Page 75: ...e 7DO So the feeder line can be raised without interference when the house is cleaned 12 Cut the drop cable long enough for installation from the winch cable through the hanger to the cable adjustment...

Page 76: ...onto the drum when the feeder line is raised must be connected to the winch cable by a throwback as shown in Figure 7DP This is a suspension drop which routes the cable away from the winch far enough...

Page 77: ...ighten winch support bolts 4 Mount the winch supports securely to the ceiling purlins BE SURE WINCH SUPPORTS SPAN THREE 3 PURLINS Winch cable drum must be centered through the centerline of the main c...

Page 78: ...er pulleys on to the cable and then attach remaining end of loop to U bolt The master pulleys must be attached to the main line cable 4 Position the cable drum as shown in Figure 7DT CABLE IS NOT TO B...

Page 79: ...ag DO NOT LIFT MOTOR BY ELECTRICAL CORDS Figure 7DW 3 Remove belt guard from winch assembly G Attach motor mount assembly to the winch frame as shown in Figure 7DX using 5 16 carriage bolts supplied i...

Page 80: ...to the main cable 10 Mount the up and down microswitches to the control channel using remaining clips and wing nuts THE ACTIVATOR ARMS ON THE SWITCHES MUST POINT TOWARDS THE END OF THE CONTROL CHANNEL...

Page 81: ...ils Setting the Microswitches The span of winching operations is determined by the space between the microswitches and can be increased or decreased by loosening the wing nuts on the microswitches and...

Page 82: ...d fill system should start System should fill until all pans are filled to proper level 3 After filling is complete turn feed switch to the OFF position 4 The DPDT toggle switch must now be to set to...

Page 83: ...d reaches the spinner motor but the paddle continues to drill through the feed c Change the pulse settings to a lower pulse using the DIP switches on the PC board d Check to see if the feed bridges ov...

Page 84: ...defective or out of alignment c1 Adjust the switch c2 Replace the switch if it is defective 5 The auger runs erratically a Note that a new auger will cause excessive noise until it is polished a Run f...

Page 85: ...h with time clock only UP BUTTON UP OFF DOWN UP LIGHT DOWN LIGHT DOWN BUTTON FILL SWITCH FILL SYSTEM LIGHT TERMINAL STRIP CLOCK SWITCH CLOCK MOTOR FILL SYSTEM R B W BK Y G CEILING CONTROL UNIT UP MICR...

Page 86: ...grams 86 PNEG 250 Hi Lo and PRO 1 Pan Feeders Microswitch End Control 220V 1 Phase 7101483 120 Cord line power 36 Cord To power unit Green Yellow Green White Blue Brown Black Common Normally closed No...

Page 87: ...to the terminals marked L1 L2 and L3 Connect to L1 20 Amp microswitch 07101483 3 208V 230V 3 Phase control unit used on 07101482 3 Coil voltage 200V 240VAC 25 amp Black Attach motor leads to T1 T2 and...

Page 88: ...l 220V 1 Phase 7101540 Ref Part Description A 20 5060 Switch Toggle SPST 15A with ON OFF B 07101123B C H Wires Black C 7101123 C H Wires White D 7100348 Cord 120 Long 14 3 E C2200025 Switch 20 Amp Uni...

Page 89: ...ld wire appropriately sized wire dashed from center control to end control as displayed End Control Center Control Normally closed Normally open Common Dashed lines indicate field wiring Wire and conn...

Page 90: ...r 215 VAC 230 VAC with appropriately sized wire to end control as displayed End Control To Motor Red L2 Black L1 Green Gnd Red Earth Earth Green Line 2 Line 2 Black Red N C N O Com Line 1 Auger Relay...

Page 91: ...ter Control Output power to end control Red L2 Black L1 Green Gnd Red Earth Earth Green Line 2 Line 2 Black Red N C N O Com Line 1 Auger Relay Green Black Green Black Red White 12 VDC Out IR Sensor co...

Page 92: ...leads to T1 T2 and T3 as displayed 208 Volt 230 Volt 3 phase control box Coil voltage 200 VAC 240 VAC 25 amp To Motor To change the direction of motor rotation reverse any two 2 motor leads Input pow...

Page 93: ...ntrol Input power 215 VAC 230 VAC Red L2 Black L1 Green Gnd IR Sensor cord Center control ON OFF switch IR Sensor cord Green Earth Earth Line 2 Line 2 Black Red N C N O Com Line 1 Auger Relay Green Bl...

Page 94: ...to end control as displayed 2 Attach plug from LED light assembly to 12 VDC out terminal as displayed Red L2 Green Gnd Black L1 To Motor Green Earth Earth Red Red Black Line 2 Line 2 Red Black Green...

Page 95: ...9 Wiring Diagrams PNEG 250 Hi Lo and PRO 1 Pan Feeders 95 Proximity Switch End Control 220V 1 Phase 7100842 Line power Blue Black Brown Green B l u e B r o w n Blue Green Brown Coil To motor...

Page 96: ...and PRO 1 Pan Feeders Proximity Switch Center Control 220V 1 Phase C2000528 Ref Part Description A 7101128 Relay Assembly for Proximity Units 1 Phase B S 7368 Switch DPDT ON ON Toggle 15 Amp White Re...

Page 97: ...Control 1 Field wire appropriately sized wire dashed from center control to end control as displayed Center Control End Control Black Red Black Coil White Blue Green Brown Line power Black White Blac...

Page 98: ...s Spinner End Control 110V 1 Phase 7100614 Line power Ground Green Yellow Red Blue DC Motor OPEN Green Yellow Blue Brown Brown L1 Out L1 In L2 L2 Black Black Black Blue Red Spinner motor To motor Swit...

Page 99: ...9 Spinner End Control 220V 1 Phase 7100211 Line power Ground Green Yellow Red Blue DC Motor OPEN Green Yellow Blue Brown Brown L1 Out L1 In L2 L2 Black Black Black Blue Red Spinner motor To motor Swit...

Page 100: ...0 PNEG 250 Hi Lo and PRO 1 Pan Feeders Spinner Center Control 110V 220V 1 Phase C2000306 Ref Part Description A S 7398 Connector 3 8 Cord 14 3 B 7100275 Nut Conduit 3 8 C S 7399 Jamb Nut 3 8 D E171 A1...

Page 101: ...WR 18 Black E106 1003 3 8 B 1775 Switch ON OFF OFF Spot 3 Position C E305 0268 WR 3 WR 18 White E106 1003 1003 D E305 0270 WR 3 WR 18 White 3 8 3 8 E MH 1462 Nut 16 Gauge Wire F 7100409 Terminal Femal...

Page 102: ...isplayed and mount to end control 4 Field wire appropriately sized wire dashed lines from switch box to center control as displayed Dashed lines indicate field wiring Wire not supplied Center Control...

Page 103: ...TS GSI shall not be liable for any direct indirect incidental or consequential damages including without limitation loss of anticipated profits or benefits The sole and exclusive remedy is set forth i...

Page 104: ...d 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 P...

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