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GSI Electronics APCD-500 User Manual

Chain disk controller
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APCD-500
User's manual
M 890-00472 REV11
Chain Disk controller
APCD-500
AUTO DROP FEED CONTROL
STATUS
RUN TIME HISTORY
TIME / DATE
FEED CYCLES
INSTALLATION
MANUAL MODE
ALARM
CURRENT OVERLOAD
CHAIN DISK
SAFETY SWITCH
MAX RUN TIME
FEED SWITCH
CHAIN DISK
AUGER
ACTUATOR OPEN
ACTUATOR CLOSE
MANUAL
AUTO
REV. 11

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Summary of Contents for GSI Electronics APCD-500

  • Page 1 APCD-500 Chain Disk controller User’s manual APCD-500 AUTO DROP FEED CONTROL STATUS ALARM CURRENT OVERLOAD RUN TIME HISTORY CHAIN DISK TIME / DATE SAFETY SWITCH FEED CYCLES MAX RUN TIME FEED SWITCH INSTALLATION CHAIN DISK MANUAL MODE AUGER ACTUATOR OPEN...
  • Page 2 The warranty can be void if this product is used in a manner not specified by the manufacturer. Every effort has been made to ensure that this manual is complete, accurate and up-to-date. The information contained in it is however subject to change without notice due to further developments. APCD-500, rev11...

  • Page 3: Table Of Contents

    4.2.2. Independent Chain Disk Systems with a Common Auger ..23 4.2.3. Independent Chain Disk Systems with Individual Augers ..23 4.3. Feed Distribution Modes ..............24 4.3.1. Timed Feed Distribution ............. 24 4.3.2. Continuous Feed Distribution ............. 24 4.4. Filling Process ..................25 APCD-500, rev11...
  • Page 4 Acknowledging an alarm ............55 MAINTENANCE .................. 56 TECHNICAL SPECIFICATIONS ............57 TRANSFER MENU ................58 8.1. Communication Speed ...............58 8.2. Screen Contrast ..................58 8.3. Update/Backup with a USB drive ............58 ANNEX 1: CORE CARD ................60 INDEX ......................61 APCD-500, rev11...

  • Page 5: Introduction

    - Use only specified replacement parts. The following guidelines must be followed to ensure safe usage of the product: - Installation must only be performed by qualified service personnel - Installation must comply with local and national safety codes APCD-500, rev11...

  • Page 6: General Safety Precautions

    When reference. the service disconnecting means cannot be locked, securely fasten a Model: APCD-500 prominent warning device, such as a tag, to the service panel. Serial number: Date installed: APCD-500, rev11...

  • Page 7: General Safety And Electrostatic Discharge Prevention

    If no wrist strap is available, ground yourself by touching the metal part that is grounded. For safety, periodically check the resistance value of the antistatic strap. It must be between 1 and 10 Mega ohms (Mohm). APCD-500, rev11...

  • Page 8: User Interface

    Turns on when the drive unit of the Chain Disk has reached its safety safety switch switch; flashes when this occurs to a slave Chain Disk (APCD-500-S). Turns on when the run time of the Chain Disk exceeds the Max Run Max run time Time parameter value (only if a proximity sensor is used);...

  • Page 9: Adjusting A Parameter

    When it is selected, press MODIFY to display the pop-up window for adjusting the parameter. Now, use the arrow keys to modify the parameter’s value and then press the MODIFY button again to validate the change. APCD-500, rev11...

  • Page 10: Mounting Instructions

    Be sure power is off the drywall, mount the enclosures onto a before doing any wiring to avoid wooden or metal frame. Do not mount the electrical shocks and equipment enclosures directly onto the drywall. damage. APCD-500, rev11...

  • Page 11: Connections

    3. The main supply circuit breaker for Chain Disk motor (L1/L2 POWER IN) shall be no larger than 20 A. 4. Wire gage used for mains supply (L1/L2 POWER IN) and Chain Disk motor shall be at least 12 AWG. APCD-500, rev11...

  • Page 12: Correctly Supporting And Routing Cables

    Do not use metallic cable-holders. Use watertight compression cable glands rated IP51 for each cable used. Use silicone to seal the cable gland rated IP51 if more than one cable is use in the same cable gland. APCD-500, rev11...

  • Page 13: Connecting The Apcd Supply To A Power Source

    (L1/L2 POWER IN) and marked as the disconnecting device for the Chain Disk motor shall be at least 12 AWG. equipment. GSI Electronics recommends installing it to the left of the system or to the Refer to the wiring diagram included with right of the system enclosure.

  • Page 14: Connecting The Chain Disk Contactor And The Current Sensor

    208Vac and 240Vac. Wire gage used for mains supply (L1/L2 POWER IN) and Chain Disk motor shall be at least 12 AWG. Wiring instruction using an external con- tactor: 1. Ensure that the breaker is opened before APCD-500, rev11...

  • Page 15: Connecting The Auger Motor

    A minimum voltage rating of 300V and a marked as the disconnecting device for the minimum temperature rating of 90°C is used equipment. GSI Electronics recommends for the wires at 120/208/240Vac Refer to the installing it to the left of the system or to the wiring diagram included with this manual right of the system enclosure.

  • Page 16: Connecting The Trouble Light

    Electronics recommends installing it to the left of the system or to the right of the sys- 1. Ensure that the breaker is opened before tem enclosure. GSI Electronics recommends installing the wiring. using a DPST disconnecting switch in series with a breaker.
  • Page 17 The maximum current value is 4A to fuse it. A minimum voltage rating of 300V and a minimum temperature rating of 90°C is used for the wires at 120/208/240Vac. Refer to the wiring diagram included with APCD-500, rev11...

  • Page 18: Connecting The Toggle Switch

    Lock the enclosure when wiring is (not included) to lock the enclosure. complete or when servicing. Use the nut and bolt included or a padlock (not included) to lock the enclosure. APCD-500, rev11...

  • Page 19: Connecting The Chain Disk Safety Switch

    Use the complete or when servicing. Use the nut and bolt included or a padlock nut and bolt included or a padlock (not included) to lock the enclosure. (not included) to lock the enclosure. APCD-500, rev11...

  • Page 20: 3.3.11. Connecting The Alarm Relay

    Use the complete or when servicing. Use the nut and bolt included or a padlock nut and bolt included or a padlock (not included) to lock the enclosure. (not included) to lock the enclosure. APCD-500, rev11...

  • Page 21: Connecting The Communication Cable With An Apcd Auxiliary

    The communication network must be in- stalled in a daisy chain topology. Lock the enclosure when wiring is complete or when servicing. Use the nut and bolt included or a padlock (not included) to lock the enclosure. APCD-500, rev11...

  • Page 22: Controller Overview

    Setups In this setup, all Chain Disk Systems are connected together and share a common Up to 7 slave units (APCD-500-S) can be bin auger. When this auger starts bringing used to drive additional Chain Disk Systems. feed into the Chain Disk Systems, all drive...

  • Page 23: Independent Chain Disk Systems With A Common Auger

    Each Chain Disk System filled according to its respective parameter settings. Chain Disk Systems Filling Order Controller & ID# APCD-500-S Simultaneous Bins ID 3 Simultaneous APCD-500-S ID 2 Simultaneous APCD-500-S ID 1 Simultaneous APCD-500 MASTER APCD-500, rev11...

  • Page 24: Feed Distribution Modes

    (the drop tube is empty) Chain Disk System line after the last drop and before the fill hop- Cont. Bypass etc. Last drop Feeding Delay Delay Drive unit Proximity sensor in drop Last drop APCD-500, rev11...

  • Page 25: Filling Process

    • If the amperage draw gets higher than on the the “Critical Current Consumption” for more Chain Disk System line than the “Critical Delay”, the system stops after the last drop and will not restart. Last drop APCD-500, rev11...
  • Page 26 & Graph D Feeding Independent Chain Disk System Sec. 4.4.5 Continuous & Graph G Feeding Individual With Sec. 4.4.6 Bin Augers proximity & Graph H sensor Timed Feeding Without Sec. 4.4.6 proximity & Graph I sensor Possible Chain Disk Setup APCD-500, rev11...

  • Page 27: Filling Cascaded Chain Disk Systems With Continuous Feed Distribution Mode

    Back to step 1. Chain Disk Systems Filling Order Controller & ID# APCD-500 Last MASTER Third APCD-500-S ID 1 Bins Second APCD-500-S ID 2 First APCD-500-S ID 3 APCD-500, rev11...
  • Page 28 APCD-500 APCD-500, rev11...

  • Page 29: Filling Cascaded Chain Disk Systems With Timer Mode

    Step to section 4.4. Chain Disk Systems Filling Order Controller & ID# APCD-500 Last MASTER Third APCD-500-S ID 1 Bins Second APCD-500-S ID 2 First APCD-500-S ID 3 APCD-500, rev11...
  • Page 30 APCD-500 APCD-500, rev11...
  • Page 31 APCD-500 APCD-500, rev11...

  • Page 32: Filling Independent Chain Disk Systems With A Common Bin Auger Using Continuous Feed Distribution Mode

    Feed Delay is the amount of time required for the animals to eat the feed). Back to step 1. Chain Disk Systems Filling Order Controller & ID# APCD-500-S Last ID 3 Third APCD-500-S ID 2 Second APCD-500-S ID 1 Bins First APCD-500 MASTER APCD-500, rev11...
  • Page 33 APCD-500 APCD-500, rev11...

  • Page 34: Filling Independent Chain Disk Systems With A Common Bin Auger Using Timer Mode

    Step to section 4.4. When the “Purge Time” is over, all drive units Chain Disk Systems Filling Order Controller & ID# APCD-500-S Last ID 3 Third APCD-500-S ID 2 Second APCD-500-S ID 1 Bins First APCD-500 MASTER APCD-500, rev11...
  • Page 35 APCD-500 APCD-500, rev11...
  • Page 36 APCD-500 APCD-500, rev11...

  • Page 37: Filling Independent Chain Disk Systems With Individual Bin Augers Using Continuous Feed Distribution Mode

    Feed Delay is the amount of time required for the animals to eat the feed). Back to step 1. Chain Disk Systems Filling Order Controller & ID# APCD-500-S Simultaneous Bins ID 3 Simultaneous APCD-500-S ID 2 Simultaneous APCD-500-S ID 1 Simultaneous APCD-500 MASTER APCD-500, rev11...
  • Page 38 APCD-500 APCD-500, rev11...

  • Page 39: Filling Independent Chain Disk Systems With Individual Bin Augers Using The Timed Feed Distribution Mode

    Chain Disk System. Chain Disk Systems Filling Order Controller & ID# APCD-500-S Simultaneous ID 3 Simultaneous APCD-500-S ID 2 Simultaneous APCD-500-S ID 1 Simultaneous APCD-500 MASTER APCD-500, rev11...
  • Page 40 APCD-500 APCD-500, rev11...
  • Page 41 APCD-500 APCD-500, rev11...

  • Page 42: Feed Delivery Process

    If no actuator or air valve is used, all feed that enters into Chain Disk Systems directly falls in the feeders while the Chain Disk Systems are being filled. When they are full, the feed gradually decreases in the feeders as the animals eat. APCD-500, rev11...

  • Page 43: Parameter Settings

    Last Cycle S1/M (AUTO) 0:35 4. Use the down-arrow key to scroll the display. The daily run times of the selected Chain Disk System are displayed for the past 5 days. Run Time Hist S1 Today 1:20 APCD-500, rev11...

  • Page 44: Time & Date

    To adjust the time and date when the “Im- proper System Time” notification appears, follow the steps in section “5.3. Time & Date”. Once the time and date has been adjusted, the notification message disappears, the system clock is set, and accurate data is ensured. APCD-500, rev11...

  • Page 45: Feed Cycle Settings

    The warning message “Check Feed Cycles” is displayed in that case. The user has to validate the new feed cycle order by scrolling down the whole feed cycle menu. The warning message will then disappear. APCD-500, rev11...
  • Page 46 3. The time at which all Chain Disk Systems are full corresponds to the “Start Time” + “Max Run Time” of all Chain Disk Systems. 4. Make sure the dump is performed after all Chain Disk Systems are full. The “Dump Time” must only be defined if actuators or air valves are enabled. APCD-500, rev11...

  • Page 47: Run Time Settings

    # of Slaves — Enter the number of additional Chain Disk Systems in use. Up to 7 Slave 4. If Slave Chain Disk Systems are used, Chain Disk Systems (APCD-500-S) can be press the down-arrow key to select the “Run controlled.
  • Page 48 Feed Sensor Mstr stops detecting feed; in the second Bypass 0:30m:s APCD-500, rev11...
  • Page 49 Single phase, 60 Hz 208 - 230 Single phase, 50 Hz 190 - 230 208 - 230 Three Phase, 60Hz 2 amps over Max Current setting 10.0 Three Phase, 50Hz 10.0 Table 1: Recommended Settings as a Function of Gearbox Type APCD-500, rev11...
  • Page 50 If all Chain Disk Systems have their own bin augers, set this delay separately for each Slave Chain Disk System. The auger delay ranges from 0 to 60 minutes. Auger Delay Mstr 0:15m:s APCD-500, rev11...
  • Page 51 Chain Disk System in use (Mstr = Master Chain Disk System, S1,= APCD-500 Slave 1, S2,= Slave 2, etc.) * This parameter is Version X.X available if proximity sensors are enabled above. Shut down delay 0:10m:s APCD-500, rev11...

  • Page 52: Manual & Test Modes

    (Master Chain Disk System, All Chain Disk Systems or slave 1-7 Chain Disk Systems). Press MODIFY once again to validate. When the desired Chain Disk System is selected, activate the manual mode as shown in section 5.7.2. APCD-500, rev11...

  • Page 53: Bypassing A Chain Disk System

    8 seconds. Chain Disk System is enabled. 3. Press the down-arrow key once. The APCD-500 Master manual mode status of the air valve is dis- Status Auto/Bypas played. * This parameter is available if the air valve is enabled (see sec.5.6).

  • Page 54: Toggle Switch

    4. Press MODIFY then use the arrow keys to set the simulated current consumption. Press MODIFY to validate. * The answer is validated after 8 seconds. Do not forget to exit from the test mode when tests are completed. APCD-500, rev11...

  • Page 55: Alarms

    APCD-500-S #x Communication is disrupted between the main controller and comm alarm an APCD-500-S slave module ID# x. Chain disk is The amperage draw of the master Chain Disk System is lower not running than 0.5 A.

  • Page 56: Maintenance

    1. Open the circuit of the main sector voltage or disconnect the plug when a wall supply is used. 2. Isolate the source of the fault and cor- rect it. APCD-500, rev11...

  • Page 57: Technical Specifications

    APCD-500 TECHNICAL SPECIFICATIONS Type ........APCD-500 Operating temperature ..0 to 40°C Storage temperature ....-15 to 50°C Ambient relative humidity...Max 95% (non-condensing) Installation category ....Category II : Overvoltage category Pollution degree ....2 Altitude........Up to 2000m Housing ........IP 51 Main Supply......208/240Vac +/- 10%, 50/60Hz, 1 PHASE, 12A Max.

  • Page 58: Transfer Menu

    1. MemoryCard -> Control 2. Control -> MemoryCard 5. Simultaneously press and hold the MENU 3. Update Firmware SELECT up- and down-arrow keys for 5 sec- 4. Save EventBuffer onds to exit from the transfer menu. 5. Comm speed 6. Contrast APCD-500, rev11...

  • Page 59: Update Firmware

    LER~1.DMP file at the root of the USB drive. If this file name already exists, it will be saved under a different name (“CONTROLLER~2. DMP” for instance). This way, the controller will never erase a file on the card. APCD-500, rev11...

  • Page 60: Annex 1: Core Card

    2. Once it is inserted, the card wil stand at the 45-degree position. 2. Pull the card out of its connector. 3. Press on the card and make it clip to the main board. APCD-500, rev11...

  • Page 61: Index

    Feed cycles Manual filling 51 Activation 50 Run time Feed cycle status 42 History 42 Principle of operation 41 Max run time 50 Programming feed cycles 44 Run time settings 46 Warning 44, 51 Safety switch Status LED 8 APCD-500, rev11...
  • Page 62 Technical specifications 56 Memory card 57 Test mode 53 Menu selection 8 Status 42 Motor see Chain Disk Time Mounting instructions 10 Time and date 43 Time format 50 Toggle switch 53 Transfer menu 57 Trouble light 54 APCD-500, rev11...
  • Page 63 APCD-500 Update 57 USB drive 57 Valve see Actuator /Electric V. Version 50 Warnings Check feed cycles 44, 51 APCD-500, rev11...

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