PNEG-1895
V2 Electronic Distributor Control
Installation and Operation Manual
PNEG-1895
Date: 09-19-13
2 PNEG-1895 V2 Electronic Distributor Control
Table of Contents
Contents
Chapter 1 Safety ..................................................................................................................................................... 4
Safety Guidelines .................................................................................................................................. 4
Safety Instructions ..................... ... .... .......................................... ... ........................................................ 5
Chapter 2 Decals .................................................................................................................................................... 7
Chapter 3 Electrical Installation ........................................................................................................................... 8
Introduction ........................................................................................................................................... 8
Wire and Fitting Selection Requirements ................................... ... ... ............................................. ........ 8
Control Panel Cable to Distributor Fitting Connections ......................................................................... 9
Motor Cable to Motor Junction Box Fitting Connections ..................................... .... ... ... ... ... .... ... ... ... ... 10
Electric Motor Wiring Diagram ............................................................................................................ 11
Motor Wiring Electrical Connections ................................................................................................... 12
Sensor Wiring Connections to Connector Box .................................................................................... 13
Enclosure Covers Installation .............................................................................................................. 14
Control Panel Installation Guidelines .................................................................................................. 15
Electric Motor Connections at Control Panel ...................................................................................... 16
Sensor Terminations in Control Panel ................................................................................................ 17
Power Supply Wiring to Control Panel Electrical Connections ........................................................... 18
Chapter 4 Operation Procedures ........................................................................................................................ 19
Initializing Screen ...................................... ... .... ... ... .......................................... ... ................................ 19
Start-Up Checklist ........................................ .... .......................................... ... ...................................... 20
Main Screen ........................................................................................................................................ 21
Move Position Screen ................................................... ...................................... .... ... ... ... ... ....... ... ... ... 22
Setup Menu Screen ............................ ... ... ... .... ... ... ... .... .......................................... ... ......................... 23
Help Menu Screen .............................................................................................................................. 32
Manual Override ........................ ... .... ... .......................................... ... ............................................. ... ... 36
Chapter 5 Parts List ............................................................................................................................................. 38
12" 6 Hole 45° Distributor Assembly Electronic Control (DFB12645G-EC) ........................................ 38
Chapter 6 Retrofit Installation ..................................... .................... ...................... .............................................. 40
Electronic Distributor Control Shaft Installation ................................................................................... 40
Electronic Distributor Enclosure Installation ........................................... ............................................. 41
Sensor Plate Angle and Proximity Sensor Bracket Installation .................. ... ... ... ................................ 42
Proximity Sensor Location and Installation ......................................................................................... 43
Proximity Sensor Adjustment .............................................................................................................. 45
Encoder and Bracket Installation ........................................................................................................ 46
Installing the Connector Box and Cables ............................... .... ... ... ... .......................................... ...... 49
Motor Mounting Bracket Installation ................................. ................................................ ................... 50
Control Motor Installation .................................................................................................................... 51
Chapter 7 Troubleshooting ................................................................................................................................. 52
Error Messages ................................................................................................................................... 52
Fault Code Descriptions, Possible Causes and Solutions .................................................................. 54
Chapter 8 Schematic and Wiring Diagrams ...................................................................................................... 57
White Panel Layout ............................................................................................................................. 57
White Panel Electrical Schematic ..............................................................................................
Chapter 9 Warranty .............................................................................................................................................. 61
......... 58
PNEG-1895 V2 Electronic Distributor Control 3
1. Safety
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a
hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE is used to address practices not related to
personal injury.
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
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. To help you recognize this information, we use the symbols that are defined
below. Please read the manual and pay attention to these sections. 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
4 PNEG-1895 V2 Electronic Distributor Control
1. Safety
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.
Keep your machinery in proper working condition.
Unauthorized modifications to the machine may impair
the function and/or safety and affect machine life.
If you do not understand any part of this manual or need
assistance, contact your dealer.
Read and Understand Manual
Practice Safe Maintenance
Understand service procedures before doing work. Keep area
clean and dry.
Never lubricate, service, or adjust machine while it is in operation.
Keep hands, feet and clothing away from rotating parts.
Keep all parts in good condition and properly installed. Fix
damage immediately . Replace worn or broken p arts. Remove any
built-up grease, oil, and debris.
Maintain Equipment
and Work Area
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. Safety precautions may be
required from the personnel. Avoid any alterations to the equipment. Such alterations may produce a very
dangerous situation where SERIOUS INJURY or DEATH may occur.
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.
PNEG-1895 V2 Electronic Distributor Control 5
1. Safety
Prepare for Emergencies
Be prepared if fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
Keep Emergency Equipment
Quickly Accessible
Wear Protective Clothing
Wear close-fitting clothing and safety equipment appropriate
to the job.
Remove all jewelry.
Tie long hair up and back.
Wear safety glasses at all times to protect eyes from debris.
Wear gloves to protect your hands from sharp edges on
plastic or steel parts.
Wear steel-toed boots to help protect your feet from falling
debris. Tuck in any loose or dangling shoestrings.
A respirator may be needed to prevent breathing potentially
toxic fumes and dust.
Wear a hard hat to help protect your head.
Wear appropriate fall protection equipment when working at
elevations greater than six feet (6').
Eye Protection
Gloves
Steel-Toed Boots
Respirator
Hard Hat
Fall Protection
6 PNEG-1895 V2 Electronic Distributor Control
2. Decals
The decals are located as shown below:
DC-2159
WARNING
MOVING PARTS.
Rotating spout can
crush and cut.
Lock out power
before servicing.
CAUTION
Do not operate with access
panel removed.
Lock out power before servicing.
PNEG-1895 V2 Electronic Distributor Control 7
DC-2160
3. Electrical Installation
Introduction
This section of the manual covers the electrical installation of your GSI electronically controlled distributor
and controller assembly. If your installation is an electronic controller retrofit being installed on an existing
GSI distributor, please begin with Section 6, Retrofit Installation on Page 40 and return to this section after
completion of mechanical component installation.
Wire and Fitting Selection Requirements
NOTE: The Sensor and VFD cables are supplied in 50' increments for a maximum length of 400'.
The Sensor cable has one unterminated end and one end has a connector. The VFD cable is
unterminated at both ends.
All sensor wiring should be run in its own conduit and this conduit should be kept at least 6" away from
other conduits. Any drain wires from shielded cable should be connected to ground in the panel.
VFD wiring should be run through appropriate conduit and the wiring for the motor must not be run in the
same conduit as the wiring for the sensors.
All conduit and fittings should be outdoor rated to keep things adequately sealed, rigid conduit
is required.
These shielding and conduit requirements must be followed for your GSI Electric Distributor Controller
to function properly. Failure to follow these guidelines may result in damage to equipment or
improper operation.
Figure 3A
8 PNEG-1895 V2 Electronic Distributor Control
3. Electrical Installation
A
B B
Control Panel Cable to Distributor Fitting Connections
Conduit for motor wiring should be run out of enclosure (DEC0005) (A) to the panel installed at ground
level. Conduit for sensor wiring should be run from enc losure (DEC0005) (A) to pan el installed at ground
level. Appropriate fittings for conduit selection must be used at all connections. (See Figure 3B.)
Figure 3B Cable Fitting Connections to Distributor Enclosure
Ref # Part# Description
A DEC0005 Enclosure
B DEC0026-XXX Sensor Cable
B DEC0025-XXX VFD Cable
NOTE: “XXX” represents the length of the cable.
PNEG-1895 V2 Electronic Distributor Control 9
3. Electrical Installation
A
B
C
D
Motor Cable to Motor Junction Box Fitting Connections
Remove the four (4) motor junction box cover screws (C) and the motor junction box cover (A) as shown
in Figure 3C.
Pull motor wiring through conduit to enclosure and feed to motor junction box (B) and through provided
cord grip. Motor wiring should be routed within the enclosure to avoid close proximity to all sensor wiring.
Motor wiring should be kept at least 4" from any sensor wires. (See Figure 3C.)
Figure 3C Cable fitting connection to motor junction box.
Ref # Description
A Motor Junction Box Cover
B Motor Junction Box
C Motor Junction Box Cover Screw
D Motor Cable
10 PNEG-1895 V2 Electronic Distributor Control
3. Electrical Installation
Electric Motor Wiring Diagram
The electric motor supplied with the GSI Electronic Distributor Control system is designed to be capable
of running on either low or high voltage. The variable frequency drive (VFD) supplied with the system
supplies 230V 3 phase power and requires that the electric motor be configured for low volta ge operation.
In order to ensure proper operation, verify the motor jumpers are configured in accordance with the wiring
diagram shown for low voltage operation. (See Figure 3D.)
Figure 3D
PNEG-1895 V2 Electronic Distributor Control 11
3. Electrical Installation
A
B
C
D
E
F
Motor Wiring Electrical Connections
Connect the motor wiring to the motor wiring terminals as shown in Figure 3E. Re-install the motor junction
box cover and screws before proceeding.
Figure 3E Motor Wiring to Motor Junction Box Electrical Connections
Ref # Description
A Motor Wiring Terminal Block
BWire W
C Wire V
DWire U
E Ground Wire
F Motor Cable
12 PNEG-1895 V2 Electronic Distributor Control
Sensor Wiring Connections to Connector Box
B
A
D
E
C
Pull sensor cable through conduit to enclosure. (See Figure 3F.)
3. Electrical Installation
Figure 3F Control Panel Wiring to Junction Box Electrical Connections
Ref # Part # Description
A DEC0108 Home Proximity Sensor Cable
B DEC0105 Connection Enclosure
C DEC0106 Encoder
D DEC0109 Over-Travel Proximity Sensor Cable
E DEC0026-XXX Sensor Cable
NOTE: “XXX” represent the length of the cable.
PNEG-1895 V2 Electronic Distributor Control 13
3. Electrical Installation
Enclosure Covers Installation
Once all wiring is complete, install the two (2) side access covers (DEC0012) (A) using four (4)
1/4"-20 x 3/4" HHCS bolts (S-1429) (D) and 1/4" lock washer (S-2041) (C) each and install the bottom
enclosure cover (DEC0013) (B) using ten (10) 1/4"-20 x 3/4" HHCS bolts (S-1429) (D) and 1/4" lock
washers (S-2041) (C) as shown in Figure 3G. Ensure that no wires are pinched or damaged when
installing access covers.
Figure 3G Enclosure Covers Installation
Ref # Part # Description
A DEC0012 Side Access Cover
B DEC0013 Bottom Enclosure Cover
C S-2041 1/4" Lock Washer
D S-1429 1/4"-20 x 3/4" HHCS Bolt
14 PNEG-1895 V2 Electronic Distributor Control
3. Electrical Installation
Control Panel Installation Guidelines
The following requirements must be followed when installing and mounting the control panel:
All wiring should be performed by a licensed/qualified electrician in accordance with the National Electric
Code (NEC), state codes and local codes.
Never mount the control panel immediately beside or above heat generating equipment or directly below
water or steam pipes.
The atmosphere surrounding the control panel must be free of combustible vapors, chemical fumes and
corrosive materials.
The control panel must be easily accessible for maintenance and operation.
Mount the control panel on a flat, vertical surface using 1/4" fasteners.
Ensure that the mounting surface is sufficient to support the weight of the control panel.
Rigid conduit connections must be placed either at sides or bottom of the control panel.
PNEG-1895 V2 Electronic Distributor Control 15
3. Electrical Installation
A
B
E
C
D
Electric Motor Connections at Control Panel
Connect the motor wiring to the terminals on the Variable Frequency Drive (VFD) in the control panel
as shown in Figure 3H. Please note that the U-V-W order of the wires is not configured as labeled on
the VFD. Motor wiring should be kept as far away from sensor wiring terminal blocks as the installation
configuration permits.
Figure 3H Control Panel Wiring from Motor Electrical Connections
Ref # Description
16 PNEG-1895 V2 Electronic Distributor Control
A Ground Terminal Block
BWire U
C Wire W
DWire V
E Ground Wire
Sensor Terminations in Control Panel
1. Sensor terminal block
2. Push in screw driver
3. Push down on screw driver
4. Insert wire into open terminal
3. Electrical Installation
Figure 3I
Placing a wire into the terminal block.
NOTE: Insulation must be removed from the end of the wire for a good connection.
1. Insert a small screw driver into the square opening under the terminal.
2. Push down on the small screw driver.
3. Insert the wire into the open terminal block above the small screw driver.
4. Remove the small screw driver to secure the wire.
5. Repeat for remaining wires. (See Figure 3I.)
Wire Connections for Terminal Block
Terminal Block # Wire Connection
1 Shield
2Black
3 White
4Red
5 Green
6Orange
7 Blue
8-11 Used for Safety Interlocks
NOTE: #11 Not shown here.
PNEG-1895 V2 Electronic Distributor Control 17
3. Electrical Installation
A
B
C
D
Power Supply Wiring to Control Panel Electrical Connections
NOTE: Ensure the power supply voltage source is OFF before installation.
Install power supply cable through the control panel using suitable hardware as shown in F igure 3J.
Connect the power supply hot wires (B) to the control panel circuit breakers (C) as shown in Figure 3J.
Connect the power supply ground wire (D) as shown in Figure 3J to the ground terminal block as shown
in Figure 3H on Page 16.
Figure 3J Control Panel Wiring from Motor Electrical Connections
Ref # Description
A Power Cable Hardware
BHot Wires
C Control Panel Circuit Breakers
D Power Supply Ground Wire
18 PNEG-1895 V2 Electronic Distributor Control
4. Operation Procedures
Initializing Screen
When powering up the distributor the first screen that appears is the “Initializing” screen. (See Figure 4A.)
During a first time start-up, press the “Diagnostic Screen” button to proceed to the diagnostic screen in
order to complete start-up checklist. If the start-up checklist has already been completed, press OK to
initialize system. Distributor will move to “HOME POSITION” to verify positioning, then display the
MAIN screen.
Figure 4A Initial Start-Up Screen
PNEG-1895 V2 Electronic Distributor Control 19
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