GSi Chain Disk APCD-500 User Manual
APCD-500
STATUS
MENUS
OUTPUT MODE
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
APCD-500
AUTO DROP FEED CONTROL
Chain Disk controller
User’s manual
M 890-00472 rev.10
REV14.
APCD-500
Manufacturer
GSI Electronics
5200, Armand-Frappier
St-Hubert (Qc)
Canada J3Z 1G5
WARN ING S
The war ranty can be void if t his prod uct is used in a m anner
not specifie d by the manufacturer.
Every effort has been m ade to ens ure that t his manu al is
complete, accurate and up-to-date. The information contained in it is however subject to change without notice
due to further developments.
2
APCD-500, rev10
APCD-500
TABLE OF CONTENTS
1. INTRODUCTION .....................................................................5
1.1. Precautions ........................................................................... 5
1.2. Symbols of the Manual ........................................................... 5
2. USER INTERFACE ..................................................................6
2.1. Location of the Controls ......................................................... 6
2.2. Adjusting a Parameter ............................................................ 7
3. MOUNTING INSTRUCTIONS ....................................................7
3.1. Mounting the Controller on the Wall ......................................... 7
3.2. Connections .......................................................................... 7
4. CONTROLLER OVERVIEW .......................................................8
4.1. Features ............................................................................... 8
4.2. Chain Disk System Setups ...................................................... 8
4.2.1. Cascade Setup .................................................................8
4.2.2. Independent Chain Disk Systems with a Common Auger .......9
4.2.3. Independent Chain Disk Systems with Individual Augers ........9
4.3. Feed Distribution Modes ......................................................... 10
4.3.1. Timed Feed Distribution .....................................................10
4.3.2. Continuous Feed Distribution ..............................................10
4.4. Filling Process ....................................................................... 11
4.4.1. Filling Cascaded Chain Disk Systems with Continuous Feed
Distribution Mode .............................................................13
4.4.2. Filling Cascaded Chain Disk Systems with Timer Mode ..........15
4.4.3. Filling Independent Chain Disk Systems with a Common Bin
Auger using Continuous Feed Distribution Mode ...................18
4.4.4. Filling Independent Chain Disk Systems with a Common Bin
Auger using Timer Mode ....................................................20
4.4.5. Filling Independent Chain Disk Systems with Individual Bin Au-
gers Using Continuous Feed Distribution Mode .....................23
4.4.6. Filling Independent Chain Disk Systems with Individual Bin Au-
gers Using the Timed Feed Distribution Mode .......................25
4.5. Feed Delivery Process ............................................................. 28
4.6. Feed Cycle ............................................................................ 28
5. PARAMETER SETTINGS .........................................................29
5.1. Controller Status .................................................................... 29
5.2. Run Time History ................................................................... 29
5.3. Time & Date .......................................................................... 30
5.3.1. Adjusting Improper System Time ........................................30
5.4. Feed Cycle Settings ............................................................... 30
APCD-500, rev10
3
APCD-500
5.5. Run Time Settings .................................................................. 32
5.6. Installation Setup ................................................................... 32
5.7. Manual & Test Modes ............................................................ 37
5.7.1. Manual Filling of the Chain Disk Systems .............................37
5.7.2. Manual Start / Stop ...........................................................37
5.7.3. Bypassing a Chain Disk System ..........................................38
5.7.4. Manual Dump ...................................................................38
5.7.5. Toggle Switch ..................................................................39
5.7.6. Test Mode .......................................................................39
5.8. Alarms.................................................................................. 40
5.8.1. Acknowledging an alarm ....................................................40
6. TECHNICAL SPECIFICATIONS .................................................41
7. TRANSFER MENU ..................................................................42
7.1. Communication Speed ............................................................ 42
7.2. Screen Contrast .................................................................... 42
7.3. Update/Backup with a USB drive .............................................. 42
ANNEX 1: CORE CARD ...................................................................44
INDEX ..........................................................................................45
4
APCD-500, rev10
APCD-500
1. INTRODUCTION
1.1. Precautions
WARNING: Read and save these
instructions!
Safety may be jeopardized if the equipment
is used in a manner not specified by the
manufacturer. Carefully read and keep the
following instructions for future reference.
Although fuses at the input and outputs of
the controller protect its circuits in case of
an overload or over-voltage, we recommend
installing an additional protection device on
the controller’s supply circuit.
The room temperature where the controller
is located must always remain between 32°F
and 104°F (0°C to 40°C). Indoor use only!
To avoid exposing the controller to harmful
gases or excessive humidity, it is preferable
to install it in a corridor.
If the equipment is used in a manner not
specified by the manufacturer, the protection provided by the equipment may be
impaired.
1.2. Symbols of the Manual
Warning. Read the following text
carefully; it contains important
information which, if ignored, may
cause the controller to operate
improperly.
High Voltage. Hazard of electrical
shock. Read the message and follow
the instructions carefully.
Pay attention. The following text
contains very useful information.
Double insulation.
Both direct and alternating current
(AC/DC).
Direct current (DC).
Alternating current (AC).
For Customer Use: Enter below the serial
number located on the side of the alarm
system and keep this information for future
reference.
Do not spray water on the controller! In
order to clean the control, wipe it with a
damp cloth.
Before servicing or cleaning unit,
switch power off at service panel
and lock the switch disconnecting
means to prevent power from being
switched accidentally. When the service disconnecting means cannot be
locked, securely fasten a prominent
warning device, such as a tag, to the
service panel.
Model: APCD-500
Serial number:
Date installed:
APCD-500, rev10
5
APCD-500
2. USER INTERFACE
2.1. Location of the Controls
Function LED — This pilot light shows what
function is selected on the main menu.
Menu Select Buttons — These buttons are
used to select a function from the main menu.
LCD Display — The LCD display on the left
Function LE D
STATUS
RUN TIME HISTORY
MENUS
TIME / DATE
FEED CYCLES
INSTALLATION
MANUAL MODE
APCD-500
AUTO DROP FEED CONTROL
LCD Display
Arrow keys
Menu s elect
buttons
status LEDs
CURRENT OVERLOAD
SAFETY SWITCH
MAX RUN TIME
FEED SWITCH
ACTUATOR OPEN
ACTUATOR CLOSE
gives the current readings and parameters
to be adjusted when you select a function.
It automatically displays the STATUS menu
after 4 minutes of inactivity.
Arrow keys — The arrow keys next to the
LCD display are used to scroll down the
parameters on screen. They are also used
to change the value of the parameters inside
editing pop-up menus.
Output Status LEDs — The table below gives
the meaning of each output status pilot light :
LED MEANING
Alarm Turns on when an alarm is detected. The Chain Disk stops operating
until the alarm is acknowledged.
Current Overload Turns on when the amperage draw of the master Chain Disk exceeds
the Max Current limit for the Overload Delay or flashes when this
situation happens with a slave Chain Disk. Fix the problem and then
acknowledge the alarm to restart the system.
Chain Disk
safety switch
Max run time
Turns on when the drive unit of the Chain Disk has reached its safety
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
Time parameter value (only if a proximity sensor is used); flashes when
this occurs to a slave Chain Disk (APCD-500-S).
Feed switch Turns on when the proximity sensor detects feed.
Flashes during the Feed Bypass Delay.
Chain disk Turns on when the master Chain Disk System is running.
Auger output Turns on when the bin auger is running; flashes during the Auger
Delay.
Actuator open Turns on when the dumps are opened.
Actuator close Turns on when the dumps are closed.
Manual mode Turns on when an output is manually controlled.
Automatic mode Turns on when the automatic control mode is active.
Output
ALARM
CHAIN DISK
CHAIN DISK
AUGER
MANUAL
AUTO
STATUS
OUTPUT MODE
6
APCD-500, rev10
APCD-500
2.2. Adjusting a Parameter
Use the arrow keys to select the parameter
that needs to be adjusted. 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.
3. MOUNTING INSTRUCTIONS
3.1. Mounting the Control-
ler on the Wall
Remove the four screws in the front cover
and lif t the cover. Remove the black caps located on the three mounting holes. Mount the
enclosure to the wall using three screws. Be
sure the electrical knockouts are at the bottom of the enclosure in order to prevent water
from entering the controller. Insert the screws
into the mounting holes and tighten. Fasten
the black caps onto the mounting holes.
• Do not install rigid conduit into electrical
knockouts. Only nylon cable glands are permitted for cable or wire fastening.
• The controller has no power-on switch.
An external switch or circuit breaker shall be
included in the building installation to interrupt power to L and N electric power lines. It
shall be in close proximity to the equipment
and within easy reach of the operator. It shall
be marked as the disconnecting device for
the equipment.
• The main supply circuit breaker for Chain
Disk motor (L1/L2 POWER IN) shall be no
larger than 20 A.
• Wire gage used for mains supply (L1/L2
POWER IN) and Chain Disk motor shall be at
least 12 AWG.
• Separate circuit breaker shall be used for
auger motor.
• The mains supply breaker for auger motor
shall be 15 A.
• Wire gage used for Flex-Flo auger motor
shall be at least 14 AWG.
3.2. Connections
To connect the controller, refer to the wiring
diagram enclosed with this user’s manual.
Use the electrical knockouts provided at the
bottom of the enclosure. Do not make additional holes in the enclosure, particularly
on the side of the enclosure when using a
computer communications module.
All wiring must be done by an authorized electrician and must comply
with applicable codes, laws and regulations. Be sure power is off before
doing any wiring to avoid electrical
shocks and equipment damage.
Safety may be jeopardized if the equipment
is used in a manner not specified by the
manufacturer.
APCD-500, rev10
7
APCD-500
4. CONTROLLER OVERVIEW
4.1. Features
The APCD-500 controls the feed entry into
Chain Disk Systems and the distribution of
feed to the animals. When used in combination with APCD -500-S auxiliary units, this
controller can control up to 8 Chain Disk
Systems.
Due to its great number of options, the
APCD-500 controller can suit most Chain
Disk setups:
4.2. Chain Disk System Setups
Up to 7 slave units (APCD-500-S) can be
used to drive additional Chain Disk Systems.
These supplementary Chain Disk Systems
can share common bin augers, they can be
linked together, or they can operate independently one from another. The following
section explains the three possible Chain
Disk System setups that can be managed by
the controller. Refer to the Installation Setup
chapter to select your specific Chain Disk
System setup.
• Timed or continuous feed cycles;
• With or without proximity sensors.
• With or without actuators / air valves to
open the drops;
• With commun or individual bin augers;
• With one or multiple Chain Disk Systems;
• With cascade or independent Chain Disk
setups.
4.2.1. Cascade Setup
In this setup, all Chain Disk Systems are
connected together and share a common
bin auger. When this auger starts bringing
feed into the Chain Disk Systems, all drive
units start running to send feed towards the
farthest Chain Disk System (APCD-50 0-S
unit with the highest ID number). When the
farthest Chain Disk System is full, the feed
fills the preceding Chain Disk System, etc.
Refer to sections 4.4.1 & 4.4.2 to get
information about the filling process
in this Chain Disk System setup.
Cascade Setup
Bins
8
APCD-500, rev10
Chain Disk Systems Filling Order Controller & ID#
Last
Third
Second
First
APCD-500
MASTER
APCD-500-S
ID 1
APCD-500-S
ID 2
APCD-500-S
ID 3
APCD-500
4.2.2. Independent Chain Disk Systems with a Common Auger
Independent Chain Disk Systems that share a
common bin auger are filled following the numerical order: the master Chain Disk System
is filled first, followed by Slave System #1,
Slave System #2, etc.
Chain Disk Systems Filling Order Controller & ID#
Bins
4.2.3. Independent Chain Disk Systems with Individual Augers
Independent Chain Disk Systems that all have
their own bin auger are being filled simultaneously when a feed cycle starts. Each Chain
Disk System filled according to its respective
parameter settings.
Chain Disk Systems Filling Order Controller & ID#
Refer to section 4.4.3 & 4.4.4 to get
information about the filling process
in this Chain Disk System setup.
Last
Third
Second
First
APCD-500-S
ID 3
APCD-500-S
ID 2
APCD-500-S
ID 1
APCD-500
MASTER
Refer to section 4.4.4 & 4.4.5 to get
information about the filling process
in this Chain Disk System setup.
Bins
Simultaneous
Simultaneous
Simultaneous
Simultaneous
APCD-500-S
ID 3
APCD-500-S
ID 2
APCD-500-S
ID 1
APCD-500
MASTER
APCD-500, rev10
9
APCD-500
4.3. Feed Distribution Modes
4.3.1. Timed Feed Distribution
When feed is distributed according to a timer,
the user chooses at what time the Chain Disk
Systems start being filled and at what time
feed starts being delivered to the animals. Up
to daily 25 feed cycles can be programmed.
Refer to section 5.6 to enable the timed feed
distribution method.
Location of the optional proximity
sensor in timer mode
When feed is distributed according to a timer,
a proximity sensor can be used to stop the
Chain Disk Systems when feed is detected
(see illustration). One proximity sensor must
be located at the end of each Chain Disk
System.
Drive unit
Proxy on
the Chain
Disk System
line after
the last
drop and
before the
Last drop
fill hopper
4.3.2. Continuous Feed Distribution
The continuous feed distribution mode
ensures the system is always full: the bin
auger starts bringing feed into the Chain
Disk System as soon as it gets empty. In
this operating mode, the proximity sensor
can either be mounted in the last drop or on
the Chain Disk System line after the last drop
and before the fill hopper.
Refer to section 5.6 to specify the
location of the proximity sensor.
Continuous Mode —
Proximity sensor in the last drop
If a proximity sensor is located in the last
drop of the Master Chain Disk System, the
system is considered as being full when the
proximity sensor detects feed. Once the
system is full, the controller waits for drop
tube to empty out before launching a new
feed cycle (the drop tubes are considered as
being empty when the proximity sensor stops
detecting feed).
Proxy in Last Drop
Feed is detected
by the master
proximity sensor
(the system is full)
A new feeding cycle
starts when feed stops
being detected by the
master proximity sensor
(the drop tube is empty)
Cont.
Bypass
Feeding
Delay
Delay
etc.
10
APCD-500, rev10
Drive unit
Proximity
sensor in
Last drop
drop
APCD-500
Continuous Mode —
Proximity sensor on the Chain Disk
System Line after the Last Drop
If the proximity sensor is located on the Chain
Disk System line af ter the last drop, the system
is considered as being full when the master
proximity sensor detects feed. At that moment, the controller launches the “Continuous
Feed Delay” (which represents the amount of
time required for the animals to eat the feed).
When the “Continuous Feed Delay” has elapsed,
all Chain Disk Systems start running again
during the “Feed Bypass Delay”.
a) If the master proximity sensor still detects
feed after the “Feed Bypass Delay”, the control-
ler relaunches the “Continuous Feed Delay” and
the “Feed Bypass Delay” again since the system
is not empty yet. This process is repeated
up until the master proximity sensor stops
detecting feed.
b) If no feed is detected in the master Chain
Disk System after the “Feed Bypass Delay”, the
controller restarts a new feed cycle in order
to refill the whole Chain Disk.
Proxy in Feed Line:
Feed is detected
by the master
proximity sensor
(the system is full)
The system is
empty when no feed
is detected after the
“Continuous Feed Delay”
+ “Feed Bypass Delay”.
A new feeding cycle
then starts.
4.4. Filling Process
Operation of the Bin Auger:
At the start-up of each feeding cycle, right
after the Auger’s Delay has elapsed, the bin
auger starts bringing feed into the Chain Disk
Systems and stops when the Chain Disk System is full. There are two ways the controller
can detect that a Chain Disk System is full:
1. The proximity sensor detects feed for
5 seconds without interruption;
2. The drive unit has been running for the
“Max Run Time” parameter value (only if no
proximity sensor is used).
Bin
Auger
Feed Line
Chain Disk Overload Protection:
The controller monitors the amperage draw of
Chain Disk drive units to prevent overloading
the system:
Auger
Motor
Continuous Feeding
Delay
Last drop
Bypass
Delay
Drive unit
Proximity
sensor on
the Chain
Disk System
line after
the last
drop
•Ifthe amperageexceeds the limit “Max
Current Consumption” limit, the controller
temporarily shuts down the bin auger
while the Chain Disk keeps running in
order to discharge the feed. As the feed
load decreases the amperage draw also
decreases; the bin auger restarts when
the current consumption gets lower than
the “Max Cur rent Consum ption - Window Size”.
•Iftheamperagedrawgetshigherthan
the “Critical Current Consumption” for more
than the “Cr iti cal Del ay”, the system stops
and will not restart.
APCD-500, rev10
11
APCD-500
Refer to section 5.6 to set the bin
auger parameters
NOTE: The whole Chain Disk stops
running when an alarm is active!
Cascaded
Chain Disk
System
Type of
Chain Disk
System
Common
Bin Auger
Filling Process According to the
System Setup:
The filling process of Chain Disk System depends on your particular system setup. Locate
your par ticular application setup on the hierarchy
tree below and then refer to the proper section of
the manual to get explanations about the filling
process of the chosen option.
Continuous
Feeding
Timed
Feeding
Timed
Feeding
Sec. 4.4.1,
& Graph A
With
proximity
sensor
Without
proximity
sensor
With
proximity
sensor
Without
proximity
sensor
Sec. 4.4.2,
&
Graph B
Sec. 4.4.2,
& Graph C
Sec. 4.4.4
& Graph E
Sec. 4.4.4
& Graph F
12
Independent
Chain Disk
System
APCD-500, rev10
Individual
Bin Augers
Continuous
Feeding
Continuous
Feeding
Timed
Feeding
Sec. 4.4.3
& Graph D
Sec. 4.4.5
& Graph G
With
proximity
sensor
Without
proximity
sensor
Sec. 4.4.6
& Graph H
Sec. 4.4.6
& Graph I
Possible Chain Disk Setup
APCD-500
4.4.1. Filling Cascaded Chain Disk Systems with Continuous Feed Distribution Mode
1. Beginning the Filling Process — The fill -
ing process starts at the end of the previous
cycle (refer to point 7 below to see when a
cycle ends).
2. Emptying the Chain Disk Systems —
When the “Continuous Delay” has elapsed,
the controller activates all drive units during
the “Auge r D e l a y” to make sure all Chain Disk
Systems are empty before bringing new feed.
3. Filling the Farthest Chain Disk System —
When the “Auger De l a y” has elapsed, all drive
units keep running and the bin auger starts
bringing feed into the Chain Disk Systems.
The feed travels through all empty Chain Disk
Systems in order to reach the farthest empty
Chain Disk System (i.e, the Chain Disk with
the highest ID number).
4. The Farthest Chain Disk System is Full
— The controller knows the farthest Chain
Disk System is full when its proximity sensor
detects feed for 5 seconds without interruption. When feed is detected in the farthest
Chain Disk System, its drive unit stops and
all other Chain Disk Systems keep on running.
5. Filling the Chain Disk Systems One by One
— Each time a Chain Disk System gets full,
its drive unit stops running and the previous
Chain Disk System starts being filled.
6. The Last Chain Disk System is Full — When
the master Chain Disk System is full (last Chain
Disk System) all drive units are off and the bin
auger stops bringing feed into the system.
7. Next cycle — The next feed cycle starts
when the master Chain Disk System gets
empty:
a) If the proximity sensor is mounted in the
last drop, the next cycle starts when the
proximity sensor stops detecting feed.
b) If the proximity sensor is located at the
end of the Master Chain Disk System, the
new cycle starts if no feed is detected
after 2 delays: “Continuous Feed Delay” +
“Bypass Delay” (the “Continuous Feed Delay
is the amount of time required for the
animals to eat the feed).
Back to step 1.
Bins
Chain Disk Systems Filling Order Controller & ID#
Last
Third
Second
First
APCD-500
MASTER
APCD-500-S
ID 1
APCD-500-S
ID 2
APCD-500-S
ID 3
APCD-500, rev10
13
APCD-500
Time
The proximity sensor in the
Maste r Chain Disk System
being filled
Master Chain D isk Syste m is
detects feed for 5 seconds
The proximity sensor in the
slave’s Chain Disk System
detects feed for 5 seconds
14
GRAPH A
Chain Disk Setup : Cascaded Chain Disk Systems
Feed Distribution Mode : Continuous
Proximity sensor? : Yes
APCD-500, rev10
OFF ON OFF ON OFF
farthest one
filled in turn s, star ting with the
Slave Chain Disk Systems are bein g
(MA) Feed bypass delay (automatically dened by the controller)
(SL) Feed bypass delay (SL) Shutdown delay
OFF ON OFF ON OFF
OFF ON OFF
Continuous feed delay (MA) Auger delay (MA) Shutdown delay
APCD-500
Parameters
Status
Status
Bin Au ger
Status
Mstr C hainD
Slave C hainD
A new feed cycle sta rts
The master proximity stops detecting feed
(if proxy is in the drop)orRight after the end of the previou s cycle
(if proxy is on the Chain Disk System line
after the last drop).
APCD-500
4.4.2. Filling Cascaded Chain Disk Systems with Timer Mode
1. Beginning the Filling Process — The filling
process starts at the start-up of a feed cycle
(defined by the “C yc le Time” parameter).
2. Cleaning the Drops — If actuators are
used and the “C le an Dro p” option is enabled
in the INSTALLATION menu, the controller
opens and closes the drops 3 times in a row
to evacuate feed leftovers from the system.
3. Empt ying the Chain Disk Systems — To
ensure all Chain Disk Systems are empty
before bringing new feed, the controller activates all drive units during the “Auger De l a y” .
4. Filling the Farthest Chain Disk System —
When the “Auger De l a y” has elapsed, all drive
units keep running and the bin auger starts
bringing feed into the Chain Disk Systems.
The feed travels through all empty Chain
Disk Systems in order to reach the farthest
empty System (i.e., the Chain Disk with the
highest ID number).
5. The Far thest Chain Disk System is Full
• If a proximity se nsor is use d: the controller knows the Chain Disk System is full
when the proximity sensor detects feed
for 5 seconds. When feed is detected,
the controller stops the feed entry (bin
auger), and stops all other drive units; the
drive unit of the full Chain Disk System
keeps running for the “Shutdown Delay”
and then stops.
• If no proximity sensor is used: if no
proximity sensor is used, the controller
knows the farthest Chain Disk System
is full when the drive unit of this Chain
Disk System has been running for its
respective “Run Time”. The drive unit of
this Chain Disk System stops when its
“Run Time” has elapsed.
6. Filling the Next Chain Disk System —
When the loaded Chain Disk System stops,
the drive units of all empty Chain Disk Systems restart, and feed enters once again into
the feed lines. Steps 4 and 5 are repeated up
until all Chain Disk Systems are full.
7. Feed Dumping — When the Chain Disk system is fully full, feed is ready to be delivered
to the animals. Step to section 4.4.
Bins
Chain Disk Systems Filling Order Controller & ID#
Last
Third
Second
First
APCD-500
MASTER
APCD-500-S
ID 1
APCD-500-S
ID 2
APCD-500-S
ID 3
APCD-500, rev10
15
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