GSi Design III Series User manual

PNEG-1156
Design III Series Grain Stir-Ator
Owner’s Manual
PNEG-1156
Date: 01-30-09

2 PNEG-1156 Design III Stir-Ator
Patent Notice
The Kalke-Murphy Grain Stir-Ator is manufactured under exclusive license for United States Patent
Numbers 3580549 and 4374621. Infringing manufacturers, sellers, and users are subject to
prosecution in the Federal Courts.
STIR-ATOR is a registered trade-mark of David Manufacturing Company.
Installation Data
Date of Installation: _____________________
Serial Number: ________________________
Bin Size:______________________________
Auger Length: _________________________
Dealer Name:__________________________

PNEG-1156 Design III Stir-Ator 3
Table of Contents
Contents
Chapter 1 Safety ..................................................................................................................................................4
Safety Guidelines ............................................................................................................................... 4
Safety Instructions .............................................................................................................................. 5
Operator Qualifications ..................................................................................................................... 11
Chapter 2 Safety Decals ...................................................................................................................................12
Chapter 3 Assembly and Installation ..............................................................................................................14
Final Inspection Check List .............................................................................................................. 14
Installation of the Design III Stir-Ator ................................................................................................ 19
Track Installation .............................................................................................................................. 19
Suspension Chains .......................................................................................................................... 22
Switch Box ........................................................................................................................................ 23
Frame Rails ...................................................................................................................................... 24
Trolley ............................................................................................................................................... 25
Yokes ............................................................................................................................................... 28
Swing Arm ........................................................................................................................................ 30
Junction Box ..................................................................................................................................... 30
Trolley Drive Arm to Cable ............................................................................................................... 32
Center Suspension System .............................................................................................................. 33
Track Gear Motor ............................................................................................................................. 34
Leveler Disks .................................................................................................................................... 34
Offset Auger Option .......................................................................................................................... 35
Lifting Stir-Ator .................................................................................................................................. 36
Suspension Chain ............................................................................................................................ 39
Installing Stir-Ator Augers ................................................................................................................. 41
Chapter 4 Management and Maintenance ......................................................................................................44
Cable Tension .................................................................................................................................. 44
Chapter 5 Operation ..........................................................................................................................................46
Operation of the Design III Stir-Ator ................................................................................................. 46
Start-up Procedure (Full Bin) ............................................................................................................ 47
Track Unit Drive Sprocket ................................................................................................................ 48
Stir-Guard Operation ........................................................................................................................ 48
Storage ............................................................................................................................................. 49
Drying Guide .................................................................................................................................... 50
Chapter 6 Troubleshooting ..............................................................................................................................53
Chapter 7 Parts List ..........................................................................................................................................55
Design III Stir-Ator Track Unit ........................................................................................................... 56
Design III Stir-Ator Switch Boxes and Suspension - Drawing B ....................................................... 58
Design III Stir-Ator Yoke ................................................................................................................... 60
Design III Stir-Ator Single Auger Trolley ........................................................................................... 64
Design III Stir-Ator Double Auger Trolley ......................................................................................... 65
Design III Stir-Ator Triple Auger Trolley ............................................................................................ 66
DMC 230V - Gear Motor (502A0040) ............................................................................................... 70
DMC 440V - Gear Motor (502A0045) ............................................................................................... 71
Stir-Ator Guard Option - 230V .......................................................................................................... 72
Stir-Ator Guard Option - 440V .......................................................................................................... 73
Design III Stir-Ator Offset Auger Option ........................................................................................... 74
Chapter 8 Wiring Diagrams ..............................................................................................................................75
Design III Stir-Ator Wiring Diagram - 1 Phase - 230V - 60 Hz .......................................................... 75
Design III Stir-Ator Wiring Diagram - 3 Phase - 230V - 60 Hz .......................................................... 76
Design III Stir-Ator Wiring Diagram - 3 Phase - 460V - 60 Hz .......................................................... 77
Design III Stir-Ator Wiring Diagram - 3 Phase - 575V - 60 Hz .......................................................... 78
Chapter 9 Warranty ...........................................................................................................................................79

4PNEG-1156 Design III Stir-Ator
1. 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. 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.
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 potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may
result in property damage.
NOTE indicates information about the equipment that you
should pay special attention.
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.

1. Safety
PNEG-1156 Design III Stir-Ator 5
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 which 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.
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.
Know how to operate and adjust your equipment to obtain
the maximum efficiency. 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.
BURYING THE UNIT WILL VOID YOUR WARRANTY.
DO NOT OPERATE EQUIPMENT IN AN EMPTY BIN. To
test the unit in an empty bin, make sure no one is in the bin,
then turn power “on” and “off” immediately from the outside
of the bin. Do NOT let it run in an empty bin.
If you do not understand any part of this manual and need
assistance, contact your dealer.
Read and Understand Manual

6PNEG-1156 Design III Stir-Ator
1. Safety
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 parts. Remove any
built up grease oil and debris. Maintain Equipment
and Work Area
Stay Clear of Rotating Parts
CAUTION SHOULD BE EXERCISED if it is necessary
to enter the bin while the equipment is in operation.
Entanglement in rotating augers will cause serious
injury or death.
Keep all shields and covers in place at all times.
Wear close fitting clothing. Stop and lock out power
source before making adjustments, cleaning, or
maintaining equipment. Rotating Auger Hazard
Operate Motor Properly
To avoid serious injury or death, stay away from unit and make sure
everyone is clear of the equipment before starting or operating
the unit.
All electrical connections should be made in accordance with
the National Electric Code. Be sure equipment and bins are
properly grounded.
Do not operate electric motor equipped units until motors are
properly grounded.
Disconnect power on electrical driven units before resetting
motor overloads.
Do not repetitively stop and start the drive in order to free a plugged
condition. Jogging the drive in this manner can damage the
equipment and/or drive components.
Electric Shock Hazard

1. Safety
PNEG-1156 Design III Stir-Ator 7
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
Avoid Falls
Anchor the bottom of any ladder being used in a bin or silo
to prevent it from slipping.
Because the equipment is suspended from chains in the
center, be cautious of positioning ladder against the
equipment. The equipment can move or swing from the
weight of a person climbing on the ladder.
When setting a ladder against the equipment, a vise grip
or other type of tie down should be used in the front and
back of the track drive unit. This keeps the equipment from
rolling or sliding around the bin while service work is
being performed.
During heavy service work, such as removing auger
drive, electric motors, or replacing electrical swivel, tying
the ladder to the main frame or other solid component
is advised.
Never climb out on the main beam or augers from a ladder
or the roof manhole.
If an unusual amount of service work needs to be
performed, consider lowering the unit onto sawhorses.
Always Use Ladders Safely

8PNEG-1156 Design III Stir-Ator
1. Safety
Wear Protective Clothing
Wear close fitting clothing and safety equipment appropriate
to the job.
Remove all jewelry.
Long hair should be tied up and back.
Safety glasses should be worn at all times to protect eyes
from debris.
Wear gloves to protect your hands from sharp edges on
plastic or steel parts.
Wear steel toe boots to help protect your feet from falling
debris. Tuck in any loose or dangling shoe strings.
A respirator may be needed to prevent breathing potentially
toxic fumes and dust.
Wear 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 Toe Boots
Respirator
Hard Hat
Fall Protection

1. Safety
PNEG-1156 Design III Stir-Ator 9
1. Read and understand the Owner’s Manual.
2. Keep all safety shields in place.
3. Disconnect all electrical power prior to inspecting, servicing, lubricating, or
adjusting the equipment.
4. Keep hands, feet and clothing away from moving parts while in operation.
NEVER stand or sit on unit while in operation.
5. To avoid serious injury or death, stay clear of the unit and make sure everyone
else is clear of the Stir-Ator before starting or operating the unit.
6. DO NOT operate the Stir-Ator unless shut off chain has been properly installed
and adjusted.
7. Never enter the bin while the Stir-Ator is in operation.
8. Exercise care when starting the Stir-Ator in a full bin of grain. Augers can be
stuck in the grain causing damage to the Stir-Ator or to the bin.
9. Operating the Stir-Ator during bin unloading can be beneficial to the unloading
process as well as prevent auger damage.
10. BURYING THE UNIT WILL DAMAGE THE BIN AND WILL VOID THE WARRANTY.
11. DO NOT OPERATE DESIGN III STIR-ATOR IN AN EMPTY BIN. To test the unit in
an empty bin, make sure no one is inside the bin, then turn power “ON” and
“OFF” immediately from the outside of the bin. DO NOT let the Stir-Ator run in
an empty bin. Damage to Stir-Ator and bin can result.
12. All electrical hook-ups must be in accordance with the National Electrical Code.
Be sure equipment and bins are properly grounded.
13. When not operating the unit for extended periods of time, or in some cases while
emptying the bin, it may be best to position the trolley at the binwall to eliminate
possible Stir-Ator or bin damage.
Familiarize yourself with the machine before operating. This will help you to
operate the Design III Stir-Ator more efficiently and obtain better quality results.
BE A SAFE OPERATOR

10 PNEG-1156 Design III Stir-Ator
1. Safety
1. Turn OFF and lock out power source.
2. A safe ladder should be used.
3. When setting a ladder against the Stir-Ator, use a vise grip or other type of tie
down in front and back of the track drive unit. Thiswill prevent the Stir-Ator from
rolling or sliding around the bin while service is performed.
4. Because the Stir-Ator is suspended from chains in the center, exercise caution
whenever placing a ladder against the unit. TheStir-Ator can moveor swing from
the weight of a person climbing on the ladder.
5. Climbing out on the main frame from either a ladder or roof manhole should NOT
be attempted. The Stir-Ator can swing, causing a fall.
6. During heavy service work, such as removing auger drive, electric motors, or
replacing electrical swivel, secure the ladder to the main frame or other solid
component.
7. Use rubber pads or other anti-slip devices to prevent the ladder from slipping on
the bin or silo floor. Slipping could cause a serious accident.
8. DO NOT climb Stir-Ator down augers to make adjustments or repairs. Slipping
could cause falling, bodily injury, or both.
9. If an unusual amount of service work is to be performed on a Stir-Ator, consider
removing the augers and lowering the unit onto sawhorses.
10. Exercise caution when using a ladder to perform work in a partially filled grain
bin. The ladder may sink into the grain and cause a fall.
Read and heed all safety reminders listed below.
To perform service work on a stirring device installed in a bin:
SAFETY FIRST PAYS

1. Safety
PNEG-1156 Design III Stir-Ator 11
Operator Qualifications
A. The User/Operator must be competent and experienced to operate auger equipment. Anyone who
works with or around augers must have good common sense in order to be qualified. These
persons must also know and meet all other qualifications, such as:
i. Anyperson whohasnot readand/or doesnot understandalloperation andsafetyprocedures
is not qualified to operate any auger systems.
ii. Certain regulations apply to personnel operating power machinery. Personnel under the age
of 18 years may not operate power machinery, including augers. It is your responsibility, as
owner and/or supervisor, to know what these regulations are in your area or situation.
iii. Unqualified or incompetent persons are to remain out of the work area.
iv. O.S.H.A. (Occupational Safety and Health Administration) regulations state: “At the time of
initial assignment and at least annually thereafter, theemployer shall instruct every employee
in the safe operation and servicing of all equipment with which the employee is, or will be
involved”. (Federal Occupational Safety and Health Standards for Agriculture. Subpart D,
Section 1928.57 (a) (6)).
B. As a requirement of O.S.H.A., it is necessary for the employer to train the employee in the safe
operatingandsafetyproceduresfor thisauger.Thesign-offsheet isprovidedfor yourconvenience
and personal record keeping. All unqualified persons are to stay out of the work area at all times.
It is strongly recommended that another qualified person who knows the shut down procedure is
in the area in the event of an emergency.
Date Employee Name Supervisor Name

12 PNEG-1156 Design III Stir-Ator
2. Safety Decals
The decals shown on this and next page must be displayed as shown.
Replacements are available upon request. Write to the following address:
GSI Group
1004 E. Illinois St.
Assumption, IL. 62510
Phone: [phone]
Please note:
1. The decals shown below are not shown in actual size.
2. Keep decals wiped clean at all times.
3. Decals must be replaced if they are destroyed, missing, painted over or can no longer be read.
Rotating flighting will
kill or dismember.
Flowing material will
trap and suffocate.
Crusted material will
collapse and suffocate.
Keep clear of all augers.
DO NOT ENTER this bin!
Failure to heed these
warnings will result in
serious injury or death.
If you must enter the bin:
1. Shut off and lock out all power.
2. Use a safety harness and safety line.
3. Station another person outside the bin.
4. Avoid the center of the bin.
5. Wear proper breathing equipment or respirator.
DC-GBC-1A
1067022 Top of gear motor track frame.
1067021 Both sides of bottom motor
mounting rail in trolley and both sides of
optional offset. DC-GBC-A and DC-GBC-1S
Should be located at any bin entry so it can
seen and easily.
DC-889 Both
sides of swivel
box plus junction
box cover.

2. Safety Decals
PNEG-1156 Design III Stir-Ator 13
Rotating flighting will
kill or dismember.
Flowing material will
trap and suffocate.
Crusted material will
collapse and suffocate.
Keep clear of all augers.
DO NOT ENTER this bin!
Failure to heed these
warnings will result in
serious injury or death.
If you must enter the bin:
1. Shut off and lock out all power.
2. Use a safety harness and safety line.
3. Station another person outside the bin.
4. Avoid the center of the bin.
5. Wear proper breathing equipment or respirator.
DC-GBC-1A
This decal is to be located so it can easily be seen and read at any entry point into the bin or silo.

14 PNEG-1156 Design III Stir-Ator
3. Assembly and Installation
Final Inspection Check List
1. READ THE STIR-ATOR OWNER’S MANUAL BEFORE INSTALLATION. MANY SERVICE
PROBLEMS WILL BE AVOIDED IF THE STIR-ATOR IS PROPERLY INSTALLED.
2. Is there at least 10-1/4" clearance from the center of the track to the lowest part of the roof and
roof braces?
3. Are the track splices correctly installed? Consult the diagrams in the owner’s manual.
4. Is the trolley installed correctly with the arm pointing toward the center of the bin?
5. Are the bolt heads holding the yoke end to the frame on the inside on the frame rails, and the cotter
key spread on the pivot tube?
6. Is the suspension bar properly hung, LEVEL, with the end loops down? Is the 1/2" x 2" bolt holding
suspension bar tightly secured? Is the lock nut on tee fitted properly?
7. Is the suspension bar positioned so that the bin “S” hook, to which the shut off chain is attached,
is at a right angle to the switch box chain, as shown in Figure 3I on Page 22 and Figure 3K,
Figure 3L and Figure 3M on Page 23? THE POWER CORD MUST HAVE MORE SLACK THAN
THE SHUT OFF CHAIN, or the power cord could be torn out of the switch box if the Design III
should malfunction and engage the shut off.
8. Is the frame of the Design III Stir-Ator approximately 1" higher at the center of the bin for each
18' of bin diameter?
9. Are augers 3" (for bins up to 30') or 4" (for bins 33' and larger) off the drying floor at bin wall?
(See Figure 3BQ on Page 41.)
10. Were the augers deburred with a file? Were the clamp bolts torqued to 140 foot-pounds? Was the
roll pin installed correctly?
11. Did you note the instruction NOT to weld flighting at the top end of the auger?
12. Are you sure that the electrician connected the black and white wires to the 230 volt terminals in
the operating switch, and the green wire to the ground? (See Wiring Diagrams on Pages 75-78.)
BE SURE BIN IS GROUNDED.
13. Are you keeping a record of the serial number for each owner?
14. Did you make sure that the owner received and signed for his OWNER’S MANUAL, and was
instructed that reading and understanding the manual are essential for proper and efficient
operation of the Stir-Ator?
15. Did you installthe safety decals on the inside andoutside of thewalk-in door andthe manholecover?

3. Assembly and Installation
PNEG-1156 Design III Stir-Ator 15
Design III Stir-Ator Overall Dimensions
Figure 3A
See Chart on Page 16 for Dimensions A, B and C.

16 PNEG-1156 Design III Stir-Ator
3. Assembly and Installation
Design III Stir-Ator Overall Dimensions (Continued)
(See Figure 3A on Page 15.)
*14' and 15' Bin diameter available on SA only.
**18' and 18' 7'' Bin diameter available on SA and DA only.
NOTE: 1. SA frame rails are 4'' x 2'' x 1/4''
2. DA frame rails up to 36' are 4'' x 3'' x 1/4''
3. DA frame rails 36' to 48' are 5'' x 3'' x 5/16''
4. TA frame rails are 5'' x 3'' x 5/16''
Bin Diameter Dimension “A”
SA/DA Dimension “A” TA Dimension “B” DA and TA Only Dimension “C” SA - DA - TA
*14' 16-1/8" NA NA 89"
*15' 22-1/8" NA NA 95"
**18' 40-1/8" NA 114-1/2” 113"
**18' 7'' 43-5/8" NA 118" 116-1/2"
2
21' 58-1/8" 40-1/8" 132-1/2" 131"
21' 7'' 61-5/8" 43-5/8" 136" 134-1/2"
22' 64-1/8" 46-1/8" 138-1/2" 137"
22' 9'' 68-5/8" 50-5/8" 143" 141-1/2"
24' 76-1/8" 58-1/8" 150-1/2" 149"
2
24' 3'' 77-5/8" 59-5/8" 152" 150-1/2"
24' 8'' 80-1/8" 62-1/8" 154-1/2" 153"
27' 94-1/8" 76-1/8" 168-1/2" 167"
27' 10'' 99-1/8" 81-1/8" 173-1/2" 172"
28' 100-1/8" 82-1/8" 174-1/2" 173"
28' 3'' 101-5/8" 83-5/8" 176" 174-1/2"
30' 112-1/8" 94-1/8" 186-1/2" 185"
31' 118-1/8" 100-1/8" 192-1/2" 191"
33' 130-1/8" 112-1/8" 204-1/2" 203"
36' 148-1/8" 130-1/8" 222-1/2" 221"
36' 3'' 149-5/8" 131-5/8" 224" 222-1/2"
39' 166-1/8" 148-1/8" 240-1/2" 239"
40' 172-1/8" 154-1/8" 246-1/2" 245"

3. Assembly and Installation
PNEG-1156 Design III Stir-Ator 17
Figure 3B

18 PNEG-1156 Design III Stir-Ator
3. Assembly and Installation
Design III Stir-Ator Standard Equipment Shipping Weights
Stir-Ator weights and auger downpull are two (2) factors to consider when determining the extra stress
that is placed on the drying bin wall and roof.
For total weight, add Chart 1 and Chart 2 weights together.
Chart 1
Stir-Ator Shipping Weights
Chart 2
Bin Size Single Auger Double Auger Triple Auger
18' 625 770 -
21' 663 808 1030
24' 700 844 1070
27' 737 882 1112
30' 775 920 1150
33' 812 960 1200
36' 867 1014 1265
40' 905 1052 1306
42' 940 1088 1345
48' 1050 1200 1500
Additional Weight with Optional Equipment
2 HP, 1 Phase Motor 33# per Motor
2 HP, 3 Phase Motor 13# per Motor
18' Augers 5# per Auger
20' Augers 10# per Auger
Auger Downpull in Pounds Initial Startup - Wet Grain
16' Auger 14' Grain 368# per Auger
18' Auger 16' Grain 390# per Auger
20' Auger 18' Grain 410# per Auger
Auger Downpull in Pounds Normal Startup - Wet Grain
16' Auger 14' Grain 207# per Auger
18' Auger 16' Grain 241# per Auger
20' Auger 18' Grain 300# per Auger

3. Assembly and Installation
PNEG-1156 Design III Stir-Ator 19
Installation of the Design III Stir-Ator
NOTE:Priorto assemblyandinstallationconsult thebinerectionmanual ormanufacturerforany special
unit hanging or support locations.
A. Before assembling the bin, place the Design III Stir-Ator (without the augers) in the center of the
bin floor (See Figure 3C.) The top ring of the metal bin is then assembled in the usual way.
Figure 3C
Track Installation
NOTE: Thewall trackhastwo (2)different holespacings:18-15/16"on thesingleanddouble augerunits
and 12-5/8" on the triple auger units. (See Figure 3E on Page 20.)
A. The track is installed 10-1/4" distance from the eave of the bin to the center line of the track. Bins
with steeply pitched or domed roofs may allow the 10-1/4" distance to be reduced; roofs with low
or flat profiles may require more clearance. Reinforcements for the roof or roof ladder which might
interfere with the movement of the Stir-Ator should be trimmed. (See Figure 3B on Page 17.)
If this cannot be done, the 10-1/4" distance from the eave to the track bolt center line must be
increased proportionately.
B. The Stir-Ator wall track is installed as follows:
1. Fasten 3 hole connector to track using a 5/16" x 1" bolt through the first hole. (This bolt does
not go through bin.)
2. 5/16" holes for the track bolts should be drilled or punched in the bin wall progressively around
the bin 10-1/4" from the eave. Start with the double hole end of a track section, then drill or
punch a hole through the bin wall at the second hole location. Attach the track piece to the wall
using a 5/16" x 3" bolt. The bolt should go through the track, 3 hole connector, track bracket
and bin wall. Fasten with a cup washer and hex nut.

20 PNEG-1156 Design III Stir-Ator
3. Assembly and Installation
3. Use the hole in the track as a guide to drill or punch the next hole and install an additional
track bracket and bolt; repeat this process around the bin. Tighten bolts as you go.
(See Figure 3D, Figure 3E, Figure 3F and Figure 3G on Page 21.)
Figure 3D
Figure 3E
NOTE: If upon completing the circuit of the bin the last section needed is less than 3' in length, shorten
the preceding piece so that a 3' or longer section can be used as the final/last section. There
should be slightly more material than required.
3 Hole connector
5/16'' x 1'' Bolt
Track
5/16'' x 3'' Bolt