GSi PNEG-1162CEX User manual

PNEG-1162CEX
CE Compliant GSI Grain Stir-Ator
Owner’s Manual
PNEG-1162CEX
Version: 5.0
Date: 10-13-20

2 PNEG-1162CEX CE Compliant GSI Grain Stir-Ator
Declaration of Conformity
ATEX DIRECTIVE
2014/34/EU
MACHINERY DIRECTIVE
2006/42/EC
AGCO Grain and Protein
A/S Cimbria, Faartoftvej 22
P.O. Box 40, 7700, Thisted
DENMARK
The GSI Group declares thatthe machine, parts or equipment
CEX STIR-ATOR IN BIN GRAIN STIRRING MACHINES: 1, 2 OR 3 AUGER
• 1.5 kW AUGER DRIVE
• 0.12 kW TRACK DRIVE
• 400 VAC
• PENDULUM TILT SWITCH
Meets the Essential Requirements of the ATEX Directive 2014/34/EU and Machinery Directive
2006/42/EC
• Equipment Group II
• Equipment Category 3
• Combustible material Grain Dust
• Minimum ignition temperature 180°C (Maximum design surface temperature T4 = 125°C)
• Ex II3D; Ex h IIIB T125°C Dc
In accordance with the following standards:
• EN IEC 60079-0:2017
• EN ISO 80079-36:2016
• EN ISO 80079-37:2016
The equipment above must not be put into service until the machinery into which it is to be incorporated
has been declared in conformity with the provisions of all relevant Directives or until these components
have been assembled in the manner recommended in the manufacturer’s instructions PNEG-1162CEX.
Signed:
Digitally signed by Frank Ward
DN: cn=Frank Ward, o=GSI EAME Kft,
ou=GSI, [email protected], c=GB
Date: 2020.12.08 13:13:41 Z

Table of Contents
PNEG-1162CEX CE Compliant GSI Grain Stir-Ator 3
Contents
Chapter 1 Safety ..................................................................................................................................................... 4
Safety Guidelines .................................................................................................................................. 4
Cautionary Symbols Definitions ............................................................................................................ 5
Safety Cautions ..................................................................................................................................... 6
Safety Sign-Off Sheet ......................................................................................................................... 10
Maintenance ........................................................................................................................................ 11
Stir-Ator Electrical Safety .................................................................................................................... 12
Operation ............................................................................................................................................ 13
Chapter 2 Safety Decals ...................................................................................................................................... 14
Chapter 3 Bin Loading ......................................................................................................................................... 16
Chapter 4 Installation .......................................................................................................................................... 17
Track ................................................................................................................................................... 17
Suspension Chain Installation ............................................................................................................. 18
Stirrer Assembly .................................................................................................................................. 20
Trolley Drive Assembly ....................................................................................................................... 31
Center Suspension Assembly ............................................................................................................. 32
Lifting Stirrer into Position ................................................................................................................... 33
Connection to Power Supply ............................................................................................................... 34
Stir Guard ............................................................................................................................................ 34
Install Augers ...................................................................................................................................... 34
Chapter 5 Electrical Installation ......................................................................................................................... 37
ATEX Rating ....................................................................................................................................... 37
Control System .................................................................................................................................... 37
Tilt Switch ............................................................................................................................................ 38
Slip Ring .............................................................................................................................................. 38
CEX Stir-Ator Control .......................................................................................................................... 39
Wiring for CEX Stir-Ator Control Panel ............................................................................................... 40
Main Electrical Closet Wiring for Stir-Ator ........................................................................................... 41
Running Cables on Stir-Ator ............................................................................................................... 42
Commisioning ..................................................................................................................................... 44
Setting Up Tilt Switch Operation ......................................................................................................... 45
Chapter 6 Start-Up ............................................................................................................................................... 47
Start-Up in a Full Bin ........................................................................................................................... 47
Chapter 7 Parts List ............................................................................................................................................. 49
Metric Stir-Ator Assembly .................................................................................................................... 50
CE Stir-Ator Yoke Assembly ............................................................................................................... 52
Frame End Inboard Weldment Assembly ........................................................................................... 54
Frame Rail Bundle Assembly .............................................................................................................. 55
Drive Arm Assembly ............................................................................................................................ 56
CE Stir-Ator Triple Auger Trolley Assembly ........................................................................................ 57
Suspension Bar Assembly .................................................................................................................. 58
Chapter 8 Warranty .............................................................................................................................................. 59

4 PNEG-1162CEX CE Compliant GSI Grain Stir-Ator
1. Safety
Safety Guidelines
Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is
written to help you understand safe operating procedures and problems that can be encountered by the
operator and other personnel when using this equipment. Read and save these instructions.
As owner or operator, you are responsible for understanding the requirements, hazards, and precautions
that exist and to inform others as required. Unqualified persons must stay out of the work area at all times.
Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting in
SERIOUS INJURY or DEATH.
This equipment must be installed in accordance with the current installation codes and applicable
regulations,whichmustbecarefully followed inallcases. Authoritieshaving jurisdictionmustbe consulted
before installations are made.
When necessary, you must consider the installation location relative to electrical, fuel and water utilities.
Personnel operating or working around equipment must read this manual. This manual must be delivered
with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the
equipment.
ST-0001-4

1. Safety
PNEG-1162CEX CE Compliant GSI Grain Stir-Ator 5
Cautionary Symbols Definitions
Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential
safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we
use the symbols that are defined below.
DANGER
WARNING
CAUTION
NOTICE
This symbol indicates an imminently hazardous situation
which, if not avoided, will result in serious injury or death.
This symbol indicates a potentially hazardous situation
which, if not avoided, can result in serious injury or death.
This symbol indicates a potentially hazardous situation which,
if not avoided, can result in minor or moderate injury.
This symbol is used to address practices not related to
personal injury.
This symbol indicates a general hazard.
This symbol indicates a prohibited activity.
This symbol indicates a mandatory action.
ST-0005-2

1. Safety
6 PNEG-1162CEX CE Compliant GSI Grain Stir-Ator
Safety Cautions
Use Personal Protective Equipment
Eye
Protection
Hearing
Protection
Hand
Protection
Head
Protection
Respiratory
Protection Foot
Protection
Fall
Protection
• Use appropriate personal protective equipment:
• Wear clothing appropriate to the job.
• Remove all jewelry.
• Tie long hair up and back.
ST-0004-1
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.
• If you do not understand any part of this manual or
need assistance, contact your dealer.
ST-0002-1

1. Safety
PNEG-1162CEX CE Compliant GSI Grain Stir-Ator 7
Follow Safe Operating Procedures
• Do not operate Stir-Ator unless shut off chain has been properly
installed and adjusted.
• Exercise care when starting Stir-Ator in a full bin of grain. Augers
can be stuck in the grain causing damage to the Stir-Ator or bin.
• Operating the Stir-Ator during bin unloading can be beneficial to the
unloading process as well as prevent auger damage.
• Do not bury the Stir-Ator. Burying the Stir-Ator will damage the bin
and will void the warranty.
• Do not operate the Stir-Ator in an empty bin. Damage to the
Stir-Ator and bin can result.
• When not operating the Stir-Ator for extended periods of
time or in some cases while emptying the bin, it is best to position
the trolley at the bin wall to eliminate possible damage to the
Stir-Ator or bin.
ST-0011-2
Stay Clear of Rotating Parts
• Do not enter the bin while the equipment is in
operation.
• Entanglement in rotating augers will cause serious
injury or death.
• Keep all guards and covers in place at all times.
• Lock-out power source before making adjustments,
cleaning, or maintaining equipment.
ST-0008-2
Operate Motor Properly
• All electrical connections must be made in accordance with
applicable local codes (National Electric Code for the US,
Canadian Electrical Code or EN60204 along with
applicable European Directives for Europe). Make sure
equipment and bins are properly grounded.
• Lock-out power 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 drive components.
ST-0009-3

1. Safety
8 PNEG-1162CEX CE Compliant GSI Grain Stir-Ator
Maintain Equipment and Work Area
• Understand service procedures before doing work. Keep area
clean and dry.
• Never service equipment while it is operating. Keep hands, feet,
and clothing away from moving parts.
• Keep your equipment in proper working condition. Replace worn
or broken parts immediately.
ST-0003-1
Avoid Falls During Service and Installation
• Use proper fall protection equipment.
• Anchor the bottom of any ladder being used in a bin or silo to
prevent it from slipping.
• Use rubber pads or other anti-slip devices to prevent the ladder
from slipping on the bin floor.
• 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.
• 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 must 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 the 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 the ladder or
roof manhole. The equipment can swing, causing a fall.
• Do not climb Stir-Ator down augers to make adjustments or
repairs. Slipping can cause falling, bodily injury or both.
• If an unusual amount of service work needs to be performed,
consider lowering the unit onto sawhorses.
ST-0010-2

1. Safety
PNEG-1162CEX CE Compliant GSI Grain Stir-Ator 9
ST-0054-1
Use Stir-Ator Equipment Properly
• Exercise care when starting the Stir-Ator in a full bin. Augers can
be stuck in the grain which can cause damage to the Stir-Ator or
the bin.
• Burying the unit will damage the bin and will void the warranty.
• Do not operate the Stir-Ator in an empty bin.
• To test the unit in an empty bin:
— Make sure no one is inside the bin.
— Turn power “on” and “off” immediately.
• Letting the Stir-Ator operate in an empty bin will cause damage
to the unit and the bin.
Stay Clear of Hoisted Equipment
• Always use proper lifting or hoisting equipment when assembling or
disassembling equipment.
• Do not walk or stand under hoisted equipment.
• Always use sturdy and stable supports when needed for installation.
Not following these safety precautions creates the risk of falling
equipment, which can crush personnel and cause serious injury
or death.
ST-0047-1
Sharp Edge Hazard
• This product has sharp edges, which can cause serious injury.
• To avoid injury, handle sharp edges with caution and always use
proper protective clothing and equipment.
ST-0036-2

1. Safety
10 PNEG-1162CEX CE Compliant GSI Grain Stir-Ator
Safety Sign-Off Sheet
Below is a sign-off sheet thatcan be used to verify that all personnel have read and understood the safety
instructions. This sign-off sheet is provided for your convenience and personal record keeping.
Date Employee Name Supervisor Name
ST-0007

1. Safety
PNEG-1162CEX CE Compliant GSI Grain Stir-Ator 11
Maintenance
1. Stop the Stir-Ator and all other machines BEFORE entering the bin.
2. Ensure the isolator switch is locked into the “OFF” position, with the only key in your possession.
3. If access to the Stir-Ator is required when the bin is completely or partly empty, a safe means of
access must be used, preferably using a working platform.
4. If using a ladder, DO NOT place the ladder against the Stir-Ator carriage unless it has been securely
clamped on either side to prevent movement. Failure to do this could cause a fatal accident. Note
that drying floors in grain stores may be slippery and therefore the ladder should be securely fixed
before attempting to gain access.
5. When setting a ladder against the Stir-Ator, a vise grip or some type of tie-down should be used in
the front and back of the track drive unit. This keeps the Stir-Ator from rolling or sliding around the
bin while service work is being performed.
6. If an unusual amount of service work is to be performed on a Stir-Ator, removing the augers and
lowering the unit to the floor of the bin may be the safest way to repair the unit.
7. Caution needs to be exercised when using a ladder to perform service work in a partially filled grain
bin. The ladder can sink into the grain causing it to fall.
8. Notice of noise and dust hazard: The Stir-Ator runs at noise levels below 70 db and should not
present any risk to hearing. Decals indicating the possibility of dust are provided in the owner’s
manual bag and should be installed per the diagram shown on Pages 14 and 15. Dust may be
created as a normal part of the stirring function of the Stir-Ator augers and although no person should
be in the bin during the stirringoperation, some residual dust may remain in the air after theStir-Ator
has been turned “OFF”. The level of dust will vary depending on the condition of the grain. Operator’s
should assess the risk to themselves and others, as required in the EU under the Control of
Substances Hazardous to Health Regulations. They should then implement appropriate control
measures to reduce the risks to health.
9. If attending to stuck augers, NEVER attempt to release the auger without isolating the Stir-Ator first.
10.Beforerestarting theStir-Ator, ensurethatthereis nooneremaining inthe binand thatthe binaccess
door is locked/closed.
11. Remember to replace all guards before restarting.
When working on or around the Stir-Ator, it is essential that a safe system of
work is strictly followed. Failure to do so may result in serious injury to the
operator. Before carrying out any work on the Stir-Ator.

1. Safety
12 PNEG-1162CEX CE Compliant GSI Grain Stir-Ator
Stir-Ator Electrical Safety
It is recommended that the electrical system to the Stir-Ator include, at minimum, the following:
1. Main power supply protected by suitable fuses or over current circuit breaker.
2. Main electrical disconnect lock out switch which can be locked.
a. To disconnect all electrical power to the equipment and other associated equipment.
3. Service disconnect which can be locked.
a. Installed immediately adjacent to each motor.
b. Wired to disconnect all electrical power to the equipment motor.
c. May also be wired to stop other equipment if required for safety during maintenance and
servicing.
4. Emergency stops.
a. Wired to stop the equipment motor (and any other associated equipment) immediately when
pressed.
b. Must remain engaged until manually disengaged.
c. The equipment should not be able to restart immediately the emergency stop is re-set.
5. Door safety interlocks.
a. Silo door safety interlock switches shall be fitted to the lower and upper silo doors.
b. These shall be connected to stop the Stir-Ator and any equipment if the door or access hatch is
opened.
c. Re-closure of the door or access hatch must not allow equipment to immediately restart.
6. Door safety and emergency stops should be connected toa safety control circuit designed to achieve
a minimum performance level (PL) ‘c’ in accordance with EN13849.
7. The electrical supply must include a properly designed protective earth system (PE), withconnection
to all exposed and extraneous conductive parts.
8. All motors must be connected to protective earth at the terminal provided.
9. The control system to include:
a. Short circuit protection.
b. Start/stop controls (labelled 1 and 0 respectively).
c. Controls designed to default to OFF after a power interruption. (Eg: self maintained relay).
d. The equipment should not be able to immediately restart following re-establishment of power or
following the re-set of an emergency stop or other safety interlock.
10. Motor circuits must include motor over current protection, wired to stop the motor when the current
exceeds the motor full load current, stated on the motor rating plate.
11. Motor thermal protection may also be required, though this does not replace the need for motor over
current protection.
12. It is also recommended that the electrical supply is protected by earth leakage protection, such as
residual current device (RCD) or residual current circuit breaker (RCCB), to provide additional
automatic disconnection from the power in the event of a fault.

1. Safety
PNEG-1162CEX CE Compliant GSI Grain Stir-Ator 13
All electrical design, installation and testing must be carried out by a qualified electrical engineer, in
accordance with EU Directives and standards and in accordance with local laws and codes.
NOTE: The Stir-Ator carries an ATEX rating.Therefore all electrical equipment used on the Stir-Ator must
meet the same level of ATEX compliance, this includes:
1. Cable glands
2. Conduit
3. Enclosures
4. Switches
Operation
1. Read and understand the owner’s manual.
2. Keep all safety shields in place.
3. Prior to inspecting,servicing, lubricatingor adjusting the Stir-Ator,ensure the isolator switch is locked
in the “OFF” position, with the only key in the possession.
4. Do not operate the Stir-Ator unless shut off chain has been properly installed and adjusted.
5. NEVER enter the bin while the Stir-Ator is in operation.
6. In the event that an auger becomes bound, the system should be switched OFF, isolated and locked
OFF before any attempt to release the auger.
7. Operating the Stir-Ator during bin unloading can be beneficial to the unloading process as well as
prevent auger damage.
8. DO NOT OVER FILL THE GRAIN BIN. BURYING THE STIRRER WILL DAMAGE BIN AND WILL
VOID THE WARRANTY.
9. DO NOT OPERATE STIR-ATOR IN AN EMPTY BIN.

14 PNEG-1162CEX CE Compliant GSI Grain Stir-Ator
2. Safety Decals
The decals shown below and Page 15 must be displayed as shown.
1. The decals shown below and Page 15 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.
Location Decal # Decals Description
Both sides of swivel
box and above
junction box cover. DC-2163 Decal, DangerHigh
Voltage (LG), CE,
CSA Harmonized
Top of gear
motor track frame. DC-2164 Decal, Chain
Warning 2" x 4-1/2"
Both sides of bottom
motor mounting rail
in trolley and both
sides of optional
offset.
DC-2420 Decal, Warning
DC-2163
GSI Group 217-226-4421
DC-2164GSI Group 217-226-4421
Automatic Machinery
Automatické stroje a zařízení
Automatikus Machinery
автоматични машини
automatische machines
Автоматические машины
автоматичні машини
Automātiskā Mašīnas
Automatinis Machinery
machines automatiques
Maquinaria automática
macchine automatiche
automatiska maskiner
Otomatik Makina
Máquinas automáticas
Aparate
Automaattinen Machinery
DC-2420
GSI Group 217-226-4421

2. Safety Decals
PNEG-1162CEX CE Compliant GSI Grain Stir-Ator 15
On bin door covers
(It should be located
at any bin entry so it
can seen and easily.)
DC-2161 Danger, Keep Clear
of Augers
Centre Yoke
Assembly NA Rating Plate
Location Decal # Decals Description
DC-2161
Automatic Machinery
Automatické stroje a zařízení
Automatikus Machinery
автоматични машини
automatische machines
GSI Group 217-226-4421
Автоматические машины
автоматичні машини
Automātiskā Mašīnas
Automatinis Machinery
machines automatiques
Maquinaria automática
macchine automatiche
automatiska maskiner
Otomatik Makina
Máquinas automáticas
Aparate
Automaattinen Machinery
Size
Ambient temperature
106V321X4200M
SN
Date
Track
-20°C - +40°C
0.13 kW
3 x 1.5 kW
16 September 2020
Augers
II3D; Ex h IIIB T125°C Dc
3 ~
-
400 V (AC)
8.7 FLA
50 Hz
Faartoftvej 22
GSI
A/S Cimbria
P.O. Box 40, 7700, Thisted
DENMARK
STIRATOR
106V321X4200M
3
x

16 PNEG-1162CEX CE Compliant GSI Grain Stir-Ator
3. Bin Loading
User’s must be aware that the Stir-Ator will impose significant load on the bin structure. It is essential to
ensure that the structure is capable of withstanding these loads:
Stirrer System Weights
(Includes 1.5 Kw (2 HP), 3 Phase Motors)
Additional Weight due to Augers
Thrust due to Auger Operation
NOTE: Stir-Ators are available up to a maximum of 8-ring bin height. However for 8-ring bin height,
the maximum density allowed is 800 kg/m3with moisture level not exceeding 18%.
Bin Size Triple Auger
18' (5.5 m) -
21' (6.4 m) 415 Kg
24' (7.3 m) 432 Kg
27' (8.2 m) 453 Kg
30' (9.1 m) 477 Kg
33' (10.1 m) 497 Kg
36' (11.0 m) 526 Kg
42' (12.8 m) 567 Kg
48' (14.6 m) 608 Kg
16' (4.9 m) Augers 27 Kg per Auger
18' (5.5 m) Augers 31 Kg per Auger
20' (6.1 m) Augers 34 Kg per Auger
22' (6.7 m) Augers 37 Kg per Auger
Auger Thrust Initial Start-Up - Wet Grain
16' (4.9 m) Auger 14' (4.3 m) Grain 167 Kg per Auger
18' (5.5 m) Auger 16' (4.9 m) Grain 177 Kg per Auger
20' (6.1 m) Auger 18' (5.5 m) Grain 186 Kg per Auger
Auger Thrust Normal Operation - Wet Grain
16' (4.9 m) Auger 14' (4.3 m) Grain 94 Kg per Auger
18' (5.5 m) Auger 16' (4.9 m) Grain 109 Kg per Auger
20' (6.1 m) Auger 18' (5.5 m) Grain 136 Kg per Auger

PNEG-1162CEX CE Compliant GSI Grain Stir-Ator 17
4. Installation
GSI RECOMMENDS THAT YOU REFER TO THE GRAIN BIN INSTALLATION/USAGE MANUAL,
BEFORE INSTALLING THE STIR-ATOR, TO CHECK FOR ANY ADDITIONAL REQUIREMENTS FOR
THE BIN TO CARRY THE STIRRING AUGER SYSTEM.
On a new bin installation, we recommend the stirrers be installed as the bin is assembled, allowing much
of the work to be carried out at ground level.
Where stirrers are being retrofitted into existing bins, suitableaccessand lifting gearwill berequired inside
the bin.
Track
1. Track must be installed at the correct level below eaves to ensure the stirrer does not foul the roof or
other objects in the bin. See Figure 4F on Page 19 for recommended minimum dimensions.
NOTE: Internal ladders must be removed before installing stirrers.
2. Mark the correct height and drill an 8 mm hole. Note aim to drill on the top of the corrugation rather
than bottom to ensure the bracket fixes level.
3. Using the connector plate (A) and track bracket (B) as a template, drill a second 8 mm hole
(See Figure 4A.)
Figure 4A Track Installation
4. Start with the end of the track pre-drilled with two (2) holes. Fix the track through the bracket
and wall.
5. Using the hole in the track and bracket as a guide, drill the next hole and install an additional track
bracket (B) and bolt (C), repeating this procedure around the bin. (See Figure 4B.)
Figure 4B Drill 8 mm Holes
Ref # Description
AConnector Plate
B Track bracket
C
B
Ref # Description
BTrack bracket
CBolt

4. Installation
18 PNEG-1162CEX CE Compliant GSI Grain Stir-Ator
6. The final piece track will need to be cut and drilled to butt up to the first. Ensure no rough edges are
left and that the track is level and even all around the bin. (See Figure 4C.)
Figure 4C Cut Final Piece to Fit
7. Any long bin bolts (D) adjacent to the track should be cut back or reversed to ensure they do
not foul the track wheels when fitted. (See Figure 4D.)
Figure 4D Check clearance between long bin bolts.
Suspension Chain Installation
Suspension chains can now be lowered through the roof center hatch.
1. Space the suspension hooks equally apart around the center fill-hole collar. Note position in relation
to the safety shut off switch (to be fitted later). (See Figure 4E on Page 19.)
2. Lock the hooks in position using the holes provided.
3. Note, if a safety switch (D) and line is to be installed (NOT SUPPLIED), recommended locations are
as shown below.
D
Ref # Description
DBin Bolts

4. Installation
PNEG-1162CEX CE Compliant GSI Grain Stir-Ator 19
Figure 4E Suspension Bar and Chain Locations
Figure 4F Typical Safety Switch Installation
Ref # Description
ASingle/Double Auger Bar
B Triple Auger Bar
CShut Off Chain
D Safety Switch
Ref # Description
ESupport Bar

4. Installation
20 PNEG-1162CEX CE Compliant GSI Grain Stir-Ator
Stirrer Assembly
1. Separate the two (2) rails (A) and place them on two (2) saw horses and remove the two (2) bolts
holding the frame rails together, spacing them approximately 200 mm apart. (See Figure 4G.)
Figure 4G Place Stirrer Rails
2. Fit the outboard frame end (B) using six (6) flange bolts, nuts and lock washers. Ensure the bolt
heads are inside the rails. Ensure the marking 1-1/2" is uppermost when fitting the frame end (B).
(See Figure 4H.)
Figure 4H Fit Outboard Frame Ends
Ref # Description
ARails
Ref # Description
BOutboard Frame End