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GSi Cumberland PNEG-250CE Installation And Operation Manual

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CE Compliant Pan Feeders
Installation and Operation Manual -
Original Instructions
PNEG-250CE
Date: 06-10-14
PNEG-250CE

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Summary of Contents for GSi Cumberland PNEG-250CE

  • Page 1 CE Compliant Pan Feeders Installation and Operation Manual - Original Instructions PNEG-250CE Date: 06-10-14 PNEG-250CE...
  • Page 2 MACHINERY DIRECTIVE 2006/42/EC 1004 East Illinois Street, Assumption, IL, 62510, USA +1 217 226 4429 The GSI Group declares that the machine, parts or equipment Cumberland Hi Lo Pan Feeders Comprising: • Micro-switch ‘end house’ control pan part number 7101482 •...
  • Page 3 Directives, nor until these components have been assembles in the manner recommended in the attached manufacturers instructions (PNEG-250CE). Signed: Name: R Pauley Position: Engineering Manager - GSI Protein Products Date: 06-10-14 PNEG-250CE CE Compliant Pan Feeders...
  • Page 4 NOTES PNEG-250CE CE Compliant Pan Feeders...

  • Page 5: Table Of Contents

    Table of Contents Contents Chapter 1 Introduction ............................6 Chapter 2 Safety ..............................7 Safety Guidelines ...........................7 Safety Instructions ..........................8 Safety Sign-Off Sheet ..........................13 Chapter 3 Decals ..............................14 Safety Decals and Placement ......................14 Chapter 4 Calculating Weight ..........................17 Calculating Weight of Feedline at Each Suspension Point ..............17 Determine Weight of Entire System .....................17 Chapter 5 Capacities and Specifications ......................18...

  • Page 6: Chapter 1 Introduction

    1. Introduction Cumberland’s Hi-Lo Pan Feeder is a revolutionary two-stage feeder bringing together features and advantages of other systems, and introducing original and effective solutions to some persistent problems and concerns. The Pan Feeder System is designed to convey granular or powdered poultry feed from external feed bins into the poultry house.

  • Page 7: Chapter 2 Safety

    2. 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.

  • Page 8: Safety Instructions

    2. Safety Safety Instructions Our foremost concern is your safety and the safety of others associated with this equipment. We want to keep you as a customer. This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel. As owner and/or operator, it is your responsibility to know what requirements, hazards, and precautions exist, and to inform all personnel associated with the equipment or in the area.

  • Page 9: Electrical Safety

    2. Safety Operate Motor Properly In an emergency, shut down the power source. Turn OFF and lock out all power sources before performing any maintenance. Do not operate electric motor equipped units until motors are properly grounded. Disconnect power on electrical driven units before resetting motor overloads.
  • Page 10 2. Safety 5. Door safety interlocks. • Where the equipment operates on or in, an enclosed space or where access to an enclosed space might expose personnel to a hazardous area e.g. grain bin or grain dryer. • Wired to stop any equipment if the door or access hatch is opened. •...

  • Page 11: Safety Guards

    2. Safety Correct Use of the Pan Feeder System The Pan Feeder System is designed solely for the purpose of conveying granular or powdered agricultural feed products for poultry feeding. Use of the system in any other way is a misuse of the system and may endanger safety and health.
  • Page 12 2. Safety Use Caution in the Operation of this Equipment The design and manufacture of the Pan Feeding System is directed toward operator safety. However, the very nature of a Pan Feeding System requiring electrical power and possessing moving parts does present a hazard to personnel which cannot be completely safeguarded against without interfering with efficient operation and reasonable access to components.

  • Page 13: Safety Sign-Off Sheet

    2. Safety Safety Sign-Off Sheet As a requirement of O.S.H.A., it is necessary for the employer to train the employee in the safe operating and safety procedures for this auger. This sign-off sheet is provided for your convenience and personal record keeping.

  • Page 14: Chapter 3 Decals

    2.25" wide x 2.15" tall. It alerts the operator of potential injury or death from electrical shock. GSI Group 217-226-4421 DC-2272 DC-2272: The decal shown is located on the lid of the Hi-Lo control pan. It measures 3.6" wide x 1.8" tall. It alerts the operator of injury or death from electrical shock. It also instructs the operator to lock out the power before servicing.
  • Page 15 3. Decals GSI Group 217-226-4421 DC-2271 DC-2271: The decal shown is located on the hopper. It measures 2.8" wide x 1.4" tall. It alerts the operator of serious injury from coming into contact with a moving auger. It also instructs the operator to disconnect and lock out the power before servicing.
  • Page 16 3. Decals GSI Group 217-226-4421 DC-2271 DC-2271: The decal shown is located under the lid, inside the drive mount. It measures 2.8" wide x 1.4" tall. It alerts the operator to keep clear of moving parts. It also instructs the operator to disconnect and lock out the power before servicing.

  • Page 17: Chapter 4 Calculating Weight

    4. Calculating Weight The winching system used to raise and lower the feed system in the poultry house imposes additional load on the building. It is essential to confirm that the building is able to carry this extra load. Consult a structural engineer to check the building strength.

  • Page 18: Chapter 5 Capacities And Specifications

    5. Capacities and Specifications Drive Unit Figure 5A Drive Units Phase Voltage Gearbox Weight Single 1/3 or 1/2 110/220 50 or 60 Direct Drive 28.4 lbs. (12.9 kgs) Three 1/3 or 1/2 190/380//208-230/460 50 or 60 Direct Drive 28.4 lbs. (12.9 kgs) Figure 5B Pans Model...
  • Page 19 5. Capacities and Specifications Control Pans Pan Style Switch Style Weight Hi-Lo Microswitch 8.8 lbs. (4.0 kgs) End Control Hi-Lo Spinner 8.8 lbs. (4.0 kgs) Hi-Lo Proximity 8.8 lbs. (4.0 kgs) Hi-Lo Microswitch 4.1 lbs. (1.8 kgs) Center House Hi-Lo Spinner 8.8 lbs.

  • Page 20: Chapter 6 Planning The System

    6. Planning the System House Layout One-half (1/2) horsepower drive units are recommended for houses over 500' (152.4 m) long. 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 Ref # Description...
  • Page 21 6. Planning the System House Layout (Continued) Figure 6B shows a double boot feed system with the feed tank in the middle of the house. Figure 6B Ref # Description Drive Unit/Control Pan Tubing Hopper Feeder Pan Flex-Flo Fill System Bulk Feed Tank PNEG-250CE CE Compliant Pan Feeders...

  • Page 22: Chapter 7 Installation

    7. Installation Installation Sequence This manual outlines the recommended sequence for the installation of the Hi-Lo Pan Feeder System. Observing this sequence provides the safest and easiest method of installation. Do not connect the system to the electrical mains until the final stage of installation.
  • Page 23 7. Installation Two-Piece Drop Tube 1. Place the top piece of the two-piece drop tube over 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.
  • Page 24 7. Installation 4. For assembly when no shut off slide is used, the indicator bumps on the top and bottom of the drop tube pieces must be aligned. (See Figure 7F.) Failure to do so will result in feed shifting where the drop tube meets the tube.
  • Page 25 7. Installation 6. Place the feed level on the feed level stand. (See Figure 7H.) Ref # Description Feed Level Feed Level Stand Figure 7H Visually check that the clip is securely situated in a notch. If the clip does not fit into the slot, the feed level can lower and the clip can become fixed out of the notches.
  • Page 26 7. Installation 8. Place the feed level on the assembly. (See Figure 7J.) Figure 7J 9. Place the pan 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 pan while pushing down on the other side and flexing the grill.
  • Page 27 7. Installation PRO-1 Assembly Instructions 1. Align slots in drop tube (A) with tabs in drop tube extension (B) and snap together as shown in Figure 7M. 2. Align adjustment slots on lower drop tube (D) with notches on feed level adjustor (E) and snap into position as shown in Figure 7N.
  • Page 28 7. Installation 3. Slide grill (7101254) over the top of the drop tube assembly and snap the pan (7098857) onto the grill as shown in Figure 7Q. Figure 7Q Flooding Applications For flooding applications, the feeder can be used in either a locked position, which prevents the pan from collapsing or in a collapsed position to take advantage of the Hi-Lo feature.
  • Page 29 7. Installation Figure 7T Figure 7S Collapsed Pan Simply leave 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, the pan is raised into position to open the flooding windows as shown in Figure 7V.

  • Page 30: E" Feeder Assembly Instructions

    7. Installation PRO-1 Retrofit Converting a standard Hi-Lo feeder to the PRO-1 feeder is simple with the use of the PRO-1 retrofit kit (C2000235). The kit contains the drop tube extension (C2000209), 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 instructions at the beginning of this section.
  • Page 31 7. Installation 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 with the letter “E”...
  • Page 32 7. Installation 3. 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 the pan into the locking position.
  • Page 33 7. Installation 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 onto the drop tube.
  • Page 34 7. Installation 6. To adjust feeder (C), you 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).

  • Page 35: Tubing Assembly

    7. Installation Tubing Assembly Be careful, there are many sharp edges that can cut while assembling the feedline. Wear protective clothing and gloves. CAUTION NOTE: Check to see that structural members are overhead to support winching the boot and hopper. (See Winching Section on Page 66.) Every fifth (5 ) auger tube should receive an insulator bracket assembly for...
  • Page 36 7. Installation 2. If the winching system is already in place, hang the line at approximately waist level. 3. Shorten the last full length of auger tube on the line (control pan side), if the building size requires it. 4. Secure the auger tubes together with the tube clamps as shown in Figure 7AE.
  • Page 37 7. Installation Figure 7AG Ref # Ref # Description 7101478 Double Swedged Tube Tube Clamp Tube End Cut Off Double Boot 2. Count and label (number) the tubes starting from the poultry boot and ending at the control unit. It is important to count and number each “group” of tubes (from the boot to the control unit) separately.
  • Page 38 7. Installation Figure 7AK Tube Inserted into Slot on Figure 7AJ Anti-Rotation Clip Anti-Rotation Clip 5. Snap the two (2) anti-rotation clips together around each pan assembly on the tube to secure the pans. Rotate the tube to position the bottom of the pans horizontal to the floor. Continue to the next tube.

  • Page 39: Feeder Assembly Rooster Feeder

    7. Installation Feeder Assembly Rooster Feeder Two-Piece 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 Figure 7AP 3.
  • Page 40 7. Installation 4. Slide the bottom of the two-piece drop tube on the assembly, making certain the tabs are locked in place. (See Figure 7AR and Figure 7AS.) Figure 7AR Figure 7AS IMPORTANT: Top and bottom pieces of the drop tube must be oriented the correct way or feed leakage could occur.
  • Page 41 7. Installation 7. To remove the bottom of the two-piece drop tube, squeeze the finger tabs at the end of the assembly and pull the two (2) pieces apart. (See Figure 7AV.) Ref # Description Finger Tabs Figure 7AV 8. Slide the telescoping restrictor over the smaller funnel restrictor with the legs pointed down. (See Figure 7AW.) Figure 7AW 9.
  • Page 42 7. Installation 10. Place the clip into the preferred notch. (See Figure 7AY.) Visually check that the clip is securely in a notch. If the clip does not fit into the slot, the feed level can lower and the clip can become fixed out of the notches. If the clip becomes fixed while out of a slot, the feed flow can stop.
  • Page 43 7. Installation 13. Disassembly of the pan and grill may be performed by lifting on one 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.

  • Page 44: Program Chart

    7. Installation Program Chart Figure 7BF PNEG-250CE CE Compliant Pan Feeders...
  • Page 45 7. Installation Figure 7BG PNEG-250CE CE Compliant Pan Feeders...
  • Page 46 7. Installation Figure 7BH PNEG-250CE CE Compliant Pan Feeders...
  • Page 47 7. Installation Figure 7BI PNEG-250CE CE Compliant Pan Feeders...
  • Page 48 7. Installation Figure 7BJ PNEG-250CE CE Compliant Pan Feeders...
  • Page 49 7. Installation Figure 7BK PNEG-250CE CE Compliant Pan Feeders...

  • Page 50: Drive Unit/Control Pan Assembly

    7. Installation Drive Unit/Control Pan Assembly 1. Unpack the drive unit and grilled control unit. 2. Connect the drive mount (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.
  • Page 51 7. Installation 4. If the pan assembly is not provided with the control pan, assemble the Hi-Lo grill onto the control pan. (See Figure 7BP.) a. Take off drop tube. b. Place through grill. c. Replace drop tube onto control pan base. d.
  • Page 52 7. Installation 7. Wire the control pan to the drive unit motor. (See Figure 7BS.) The control pan MUST be connected to ground/earth. WARNING a. Place cord into motor connection box. a. Tighten cord connector. b. Connect wires to motor leads, matching black to brown and blue to white. Figure 7BS 8.

  • Page 53: Control Pan Assembly

    7. Installation Figure 7BV Ref # Description Vent Plug Control Pan Assembly Hi-Lo Center House Control Pan (All Clamp on Models) Figure 7BW is the Hi-Lo center house control pan with the pre-assembled double bell auger tube. The center house control pan can be mounted between two (2) sections of auger tube by trimming one auger bell as shown in Figure 7BX on Page 54 and installing it as shown in...
  • Page 54 7. Installation Figure 7BX Figure 7BY PNEG-250CE CE Compliant Pan Feeders...
  • Page 55 7. Installation If breaking the feed line is not an option, the double belled auger tube can be removed and the center house control pan can then be clamped to the feed line as shown in Figure 7BZ. 1. The outlet hole for the center house control pan and two (2) holes in front of the center house pan must be enlarged.
  • Page 56 7. Installation Adjusting the Hi-Lo Microswitch Control Pans (End and Center House) 1. Check switch and adjust if necessary. Switch should click with 6 mm of movement. (See Figure 7CC.) Figure 7CC 2. Assemble remainder of Hi-Lo pan. (See Figure 7CD.) Figure 7CD PNEG-250CE CE Compliant Pan Feeders...
  • Page 57 7. Installation 3. Wire control pan to power source. (See Figure 7CE.) Lock out power before servicing. DANGER Figure 7CE Ref # Description Power In To End Control Control Pan Electrical Box Switch Proximity Switch Sensor Adjustment All capacitive switches have a potentiometer which allows switch sensitivity to be adjusted for the best results.

  • Page 58: Auger Installation

    7. Installation Auger Installation Watch carefully for wire, tags, metal clips and especially for kinks and bends. If NOTICE the auger is bent or kinked, it must be straightened prior to operation. Otherwise, excessive auger tube wear will result. 1. Remove the bearing cap, bearing and idler shaft from the boot. 2.
  • Page 59 7. Installation Use caution when releasing the tension on the auger. If the auger moves too quickly in any direction, it can injure the operator. CAUTION 7. Mark the auger at the edge of the boot where the bearing mounts, as shown in Figure 7CG.
  • Page 60 7. Installation 11. Pull the auger out from the back of the hopper an additional 8" (20.3 cm) and clamp at that point with a pair of locking pliers. (See Figure 7CI.) 12. Allow the pliers to rest against the boot to hold the auger in place. Ref # Description Back of Hopper...
  • Page 61 7. Installation 19. The auger may be lengthened by brazing two (2) sections of auger together. (See Figure 7CK.) 20. The ends to be brazed should be well filed and cleaned. Weld length should be 1/2" to 3/4" (13 mm to 19 mm). 21.

  • Page 62: Hopper Assembly

    7. Installation Hopper Assembly Be careful, there are many sharp edges that can cut while assembling the feedline. Wear protective clothing and gloves. CAUTION The head of the bolts should be to the inside of the hopper to help prevent feed from bridging. 1.

  • Page 63: Anti-Roost Wire

    7. Installation Anti-Roost Wire 1. Double loop the anti-roost wire around the first insulator at the boot as shown in Figure 7CN. 2. Secure the anti-roost wire around the insulator with the cable clamp sleeves provided as shown in Figure 7CN.
  • Page 64 7. Installation The shocker wire is to be installed in 50' (15.24 m) increments maximum. 4. Install an anti-roost wire tension spring, as shown in Figure 7CP at the next insulator, the fifth (5 auger tube down. 5. Hook one end of the spring over the insulator of the next section of wire as shown in Figure 7CP.

  • Page 65: Hopper Level Control Switch

    7. Installation Hopper Level Control Switch Cumberland’s feed level control switches are designed to provide automatic control for the fill system on any hopper-fed feeding system. The switch should be mounted on the back (bearing) side of the feed hopper, using the provided mounting hardware. Mounting the switch as close as possible to the drop from the fill system will provide optimum operation.

  • Page 66: Winching

    7. Installation Winching Building Safety Before attempting to install a winching system, it is important to verify the structure of the poultry house can carry the added weight of the pan feeding system. WARNING Capacities and Specifications Section on Pages 18 and 19 to assess the weight to be carried.
  • Page 67 7. Installation 2. Required winch drop line locations. (See Figure 7CW on Page 69.) a. One to hang each drive unit. b. One within 3' (0.9 m) of the drive. c. Two (2) to hang each feed hopper (19" (48.26 cm) apart for 120# and 200# hoppers, 25" (63.50 cm) for 300# and 400# hoppers).
  • Page 68 7. Installation e. Bolt two (2) halves of the hopper suspension brackets using two (2) 5/16"-18 bolts and nuts. The drop cables will need to be spaced 19" 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 7CV.
  • Page 69 7. Installation Figure 7CW 3. Screw the hooks along the marked line at the recommended spacing, for wood frame installation. Screw the hooks into the ceiling supports or rafters the full length of the threads to prevent bending. For metal frame installations, some support fabrication may be necessary in order to install pulleys at the recommended spacing.
  • Page 70 7. Installation 7. For systems shorter than 360' (109.7 m), extend the 3/16" (0.476 cm) winch cable the full length of the feeder line, stringing the cable through the cable hole on the winch drum. Temporarily attach the cable to the ceiling with nails, staples or some type of fastener. The winch cable does not pass though any pulleys.
  • Page 71 7. Installation 10. Thread the 1/8" (0.3175 cm) drop cable through each pulley and attach it to the 3/16" (0.47625 cm) winch cable about 6" (15 cm) from the pulley towards the winch with the 1/8" x 3/16" (0.3175 cm x 0.47625 cm) cable clamps.
  • Page 72 7. Installation “Throwback” Installation Drops located close enough to the winch that they will wrap onto the drum when the feeder line is raised must be connected to the winch cable by a “throwback,” as shown in Figure 7DC. This is a suspension drop which routes the cable away from the winch far enough that the cable clamp sleeve and drop cable do not get wound onto the winch drum.

  • Page 73: Chapter 8 Troubleshooting

    8. Troubleshooting Safety in Maintenance and Repairs Before starting any repairs or maintenance on the Pan Feeder System observe the following safety steps: 1. Isolate the whole of the system from the electricity supply by switching OFF the power isolator and locking it.
  • Page 74 8. Troubleshooting Problem Checks Corrective Action e. Check to see if the spinner motor spins, but the feed line motor does not come e. Replace the PC board. ON and the green light does not 2. Spinner control pan will come ON.

  • Page 75: Conditions And Limitations

    14 months from arrival at port of discharge, whichever is earlier. The end-user’s sole remedy (and GSI’s only obligation) is to repair or replace, at GSI’s option and expense, products that in GSI’s judgment, contain a material defect in materials or workmanship.
  • Page 76 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.gsiag.com Cumberland is a part of GSI, a worldwide brand of AGCO Corporation. Copyright © 2014 by Group Printed in the USA CN-312570...

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