Neco SMARTstir Owner's manual

SMARTstir
Grain Stirring Machine
Owner’s & Operator’s Manual
Effective Date:
March 26, 2015
Publication Number:
030123
Rev:
C

Nebraska Engineering Company (NECO) Overview ---
Since 1959, NECO equipment has been proudly designed, manufactured, and supported for
customers here in the USA and around the world. With proper operation and maintenance,
the equipment will provide years of safe and dependable service. NECO is continually testing
and improving our products in order to provide you with the safest, most ef cient, and most
economical grain handling & grain conditioning equipment available. We welcome your questions
or comments and look forward to a continued relationship, ultimately saving you valuable time and
reducing your workload.
About this manual ---
• This manual is provided to help ensure the safety of the equipment
operator, as well as others who come into contact with the equipment.
• Keep a copy of this manual in a safe place for future reference.
• Failure to read, understand, and follow the instructions within
this manual constitute a misuse of the equipment and can affect
personnel safety and the product warranty.
• Additional copies can be viewed or printed from the NECO
website www.necousa.com or contact your local dealer for
assistance.
• Language translations of this manual are made as accurately as
possible. If translation differences do occur, the English text will
prevail.
READ
and
UNDERSTAND
Watch for this symbol - it means DANGER or CAUTION !!
Be alert to the possibility of serious injury or death.
• This symbol is used to call your attention to
instructions concerning personal safety.
• It is your responsibility as an owner, operator,
or supervisor to know what hazards exist and
to make this information known to all persons
working with the equipment or who are in the
area.
Become Alert !!
Product Changes & Improvements ---
• NECO reserves the right to make changes or improvements to its products
without incurring any obligation with respect to previously manufactured products.
Welcome to the NECO family of products --
2

***** LIMITED WARRANTY *****
For a period of one(1) year after shipment of goods by the Buyer to the
Buyer’s customer, NECO will supply, free of charge, FOB per NECO’s factory
located in Omaha, Nebraska, replacement parts for any parts that NECO
identifi es to be defective due to workmanship or material.
• This limited warranty does not extend to parts that wear due to normal operation and
need to be replaced periodically.
• Goods not manufactured by NECO carry only their manufacturer’s warranty.
• This undertaking is in lieu of all other warranties, expressed or implied, including
merchantability and  tness for a particular purpose.
• You must obtain a “Return Authority” form from NECO prior to returning any defective
goods. Those defective goods must be returned, freight-prepaid, to the NECO factory in
Omaha, Nebraska. See the back cover of this manual for complete address information.
• NECO reserves the right to make changes or improvements to products and goods
without incurring any obligation with respect to previously manufactured products.
• Failure to follow the instructions contained in this manual, as well as the existence of
any of the conditions listed below, will cause this Limited Warranty to be null and void:
1. Improper assembly.
2. Improper installation, including power and wiring.
3. Unauthorized alteration of the product or components therein.
4. Operation of the unit when repairs are needed.
5. Use of unauthorized parts.
6. Operation by children or uninstructed personnel.
7. Processing of materials that are abrasive, that do not  ow freely,
or that are otherwise unsuited for processing in farm equipment.
8. Misuse of the equipment or any of its components.
9. Damage due to negligence, abuse, or accidents.
LIMITATION OF LIABILITY
• Buyer agrees that in no event shall NECO have liability for direct damages in excess of
the contract price of the goods for which the claim is made.
• Buyer further agrees that in no event shall NECO have liability for loss of use, loss of
pro ts, or for any indirect, incidental, or consequential damages on any claim of any
kind.
3

Welcome to the NECO family of products -- ............................2
***** LIMITED WARRANTY *****.................................................3
1. SAFETY .......................................................................6
2. WARNING LABELS.....................................................8
DOMESTIC WARNING LABEL IDENTIFICATION.......................8
FRENCH WARNING LABEL IDENTIFICATION.........................10
3. EQUIPMENT OVERVIEW.........................................14
EQUIPMENT DESCRIPTION......................................................14
ASSEMBLED LAYOUT WITHIN BIN .........................................15
STANDARD COMPONENT ID....................................................16
4. ASSEMBLY & INSTALLATION.................................18
TURNKEY INSTALL FOR A NEW BIN.......................................18
ASSEMBLY PARTS I.D. .............................................................20
DETERMINE SPECIAL CLEARANCE ISSUES.........................22
TRACK INSTALLATION .............................................................24
ASSEMBLE ITEMS TO MAIN BEAM.........................................30
SECURE THE MAIN BEAM .....................................................30
MOUNT THE DRIVE CLUSTER ..............................................30
RE-POSITION THE BEAM.......................................................31
ROLL TROLLEYS ONTO MAIN BEAM....................................31
INSTALL TROLLEY SPACER BRACKETS ..............................32
INSTALL CENTER HANGER ASSEMBLY ...............................33
INSTALL HANGER CHANNEL LEGS ......................................34
INSTALL CABLE FESTOON BRACKETS................................34
INSTALL FESTOON EYE-BOLTS............................................35
INSTALL CONTACTOR SAFETY CHAIN.................................36
INSTALL CABLE & RINGS FOR WIRING................................37
INSTALL PITMAN ARM BRACKET..........................................37
INSTALL IDLER ASSEMBLY....................................................38
INSTALL TROLLEY DRIVE CHAIN..........................................39
INSTALL CHAIN TENSIONER .................................................41
INSTALL AUGER DRIVE MOTORS.........................................42
INSTALL DRIVE MOTOR PULLEY..........................................43
ELECTRICAL ROUTING & HOOKUP........................................44
MAIN DISCONNECT AMPERAGE REQUIREMENTS ............44
GENERAL WIRING NOTES.....................................................44
MOUNT MAIN JUNCTION BOX ..............................................45
MOUNT ELEC ENTRY BOX ....................................................45
MOUNT TROLLEY JUNCTION BOX .......................................46
CONTACTOR WIRING.............................................................47
GEARMOTOR WIRING ...........................................................47
TABLE OF CONTENTS
4

INCOMING POWER TO TROLLEY J-BOX..............................48
MAIN JUNCTION BOX SCHEMATIC - 1 PHASE ....................49
MAIN JUNCTION BOX SCHEMATIC - 3 PHASE ....................50
ROUTING DAPS & TROLLEY MOTOR CORDS.....................51
ROUTE & MOUNT DAPS SWITCHES ....................................52
ROUTE & CONNECT AUGER MOTOR CABLES....................53
BIN SPECIFIC INSTALLATION..................................................54
MOUNT THE HANGER BRACKETS .......................................54
RAISE & SECURE THE SMART-STIR ....................................55
ADJUST THE MAIN BEAM SLOPE .........................................58
SECURE CHAINS TO HANGER BRACKETS .........................58
INSTALL AUGER ASSEMBLIES................................................60
INSTALL MAIN DISCONNECT...................................................64
ATTACH SAFETY CHAIN SHUTOFF ......................................64
5. STARTUP & OPERATION ........................................66
OVERVIEW .................................................................................66
EQUIPMENT STARTUP .............................................................67
FILLING.......................................................................................67
OPERATION ...............................................................................68
6. MAINTENANCE.........................................................69
7. APPENDIX ................................................................71
TROUBLESHOOTING................................................................71
RESTARTING STUCK AUGERS................................................72
FACTORY WIRING SCHEMATICS.............................................74
TROLLEY JUNCTION BOX - 230V / 1P ..................................76
TROLLEY JUNCTION BOX - 230V / 3P ..................................77
TROLLEY JUNCTION BOX - 460V / 3P ..................................78
DAPS SWITCH ........................................................................79
MAIN JUNCTION BOX - 230V 1P............................................80
MAIN JUNCTION BOX - 230V 3P............................................82
MAIN JUNCTION BOX - 460V 3P............................................84
REPLACEMENT PARTS ............................................................86
OVERVIEW ..............................................................................86
SIDE VIEW - DETAIL ...............................................................86
CENTER PIVOT ASSEMBLY (#039954)..................................87
DRIVE CLUSTER ASSEMBLY (#039919) ...............................88
CHAIN TENSIONER ASSEMBLY (#039984) ...........................90
TROLLEY ASSEMBLY (#039922)............................................92
TROLLEY ROLLER ASSEMBLY (#039924) ............................93
TROLLEY ASSEMBLY MISC ...................................................94
DAPS SWITCH (#030063) .......................................................95
PITMAN ARM (#030109)..........................................................96
DRAFT LINK ASSEMBLY (#030142) .......................................96
STIRRING AUGER...................................................................97
4. ASSEMBLY & INSTALLATION (CONTINUED)
5

** Federal Occupational Safety & Health Standards for
Agriculture Subpart D, Section 1928.57 (a)(6).
WORK AREA SAFETY
• Work Area is dened as the area surrounding
grain handling equipment.
• Make sure that no children or unauthorized
persons enter the work area.
• If anyone not involved in the actual operation
DOES enter the work area, the operator
on duty should immediately shut down the
equipment until all unauthorized persons are
safely out of the work area.
• Prior to start-up and during operation, make
sure that the work area is clean and free of
any tools and debris. KEEP AREA CLEAN.
WEAR PERSONAL PROTECTIVE
EQUIPMENT (PPE)
• Utilize protective equipment, such as:
Hand protection, ear plugs, eye shields,
conned space equipment, and fall
protection equipment - to mention a few.
ANSI and NFPA STANDARDS
• Install all equipment in compliance with
ANSI and NFPA Standards.
OPERATOR QUALIFICATIONS
• Anyone who has not read or does not
completely understand all operating and
safety instructions contained within this
manual is not qualied to operate the
equipment.
• Only competent and experienced persons
should operate farm equipment. Anyone
operating or working around power
equipment must understand and meet all
legal and contractual requirements.
• The owner / operator must know the
regulations in your own area. For example,
some regulations specify that no one
under the age of 16 may operate power
machinery including farmstead equipment.
• Current OSHA regulations state in part,
“At the time of initial assignment and at
least annually thereafter, the employer
shall instruct every employee in the safe
operation and servicing of all equipment
with which the employee is, or will be
involved. **
• Know and use proper LOCK OUT / TAG
OUT procedures and know the emergency
shut-off locations of any and all utilities
connected to the equipment.
OPERATING PROCEDURES
• Safely follow all operating procedures
outlined within this manual.
• Prior to startup, make sure that all safety
shields and warning decals are in place.
• NEVER leave equipment running without a
qualied operator present.
• Inspect the equipment periodically and be
alert for unusual noises, vibrations.
1. SAFETY
READ
and
UNDERSTAND
6

EQUIPMENT INSPECTION
• LOCK OUT & TAG OUT the equipment
prior to any inspection, adjustment, service,
or maintenance.
• Inspect the equipment after assembly,
before each use, and end of season.
DRIVES AND LOCKOUTS
• Make sure the power disconnect switch
can be locked in the OFF position. This
disconnect switch must be locked whenever
work is being performed on the equipment.
• Inspect all power drives before adding
power. Chains, belts, etc. should have
proper tension or be adjusted prior to
running.
• Electric motors and controls must be
installed by a qualied electrician. They
must meet the standards set by the NFPA
Std 70 of the National Electrical Code and
all local and state codes.
• Disconnect power before resetting motor
overloads.
BIN SAFETY
• Never enter a bin without being monitored
by another person.
• Do not enter the grain bin unless all power
to equipment has been LOCKED OUT &
TAGGED OUT.
• Use a safety harness and safety line when
inside the bin.
• Avoid walking on grain near the grain
outlets. Flowing grain can trap and
suffocate.
• Do not enter the bin if the grain has not
owed out of the bin normally. Moisture in
the bin can cause grain to form steep,
unstable inclines or bridges as shown in the
diagrams below:
Crusted Grain Forming Steep Inclines
Crusted Grain Forming a Bridge
Failure to observe these safety instructions can result in injury or death !!
7

2. WARNING LABELS
DOMESTIC WARNING LABELS TO BE PLACED ON BIN
LABEL
ID WARNING LABEL HEADER PART #QTY LOCATION
ADanger—Rotating Augers 1002306 2 See Bin Warning Labels
B Danger—Flowing grain traps and suffocates 1002308 2 See Bin Warning Labels
C Danger—Electrocution Hazard 1002309 2 See Bin Warning Labels
DOMESTIC WARNING LABELS TO BE PLACED ON EQUIPMENT
ADanger—Rotating Augers 1002306 AS
REQD See Equipment Warning Labels
D Danger—Rotating Pulley 035690 AS
REQD See Equipment Warning Labels
E Warning—High Voltage 035691 3 See Equipment Warning Labels
Warning Label Overview
• Occupational safety is one of NECO’s primary concerns. Warning labels that conform to
industry standards are provided to identify potential safety hazards that could cause harm
and to INCREASE YOUR AWARENESS OF THE HAZARD.
• It is the Owners & Operators responsibility to ensure that all instructions identied by
warning labels are followed - including any usage of personal protective equipment (PPE).
• This following warning label information identies:
1. Potential hazards that are identied by a warning label.
2. Warning label header or identication.
3. The NECO part number for that warning label.
4. The location of that warning label.
5. What that warning label looks like - note that label pictorials are not shown full size.
• If the warning labels are missing or become unreadable in any way, use the following
information to determine the required part number and contact NECO Customer Service at
402-453-6912 or toll free at 800-367-6208 for replacements.
• Replacement Warning Labels will be sent to you FREE OF CHARGE.
• Surfaces must be free of oils, dirt and moisture before applying replacement warning labels.
DOMESTIC WARNING LABEL IDENTIFICATION
8

A. Danger—Rotating Augers
C. Danger—Electrocution Hazard
B. Danger—Flowing Grain D. Danger—Rotating Pulley
E. Warning—High Voltage
PLACED ON BIN:
A. Danger—Rotating Augers
PLACED ON EQUIPMENT:
9

FRENCH WARNING LABELS TO BE PLACED ON BIN
LABEL
ID WARNING LABEL HEADER PART #QTY LOCATION
ADanger—Rotating Augers 1002312 2 See Bin Warning Labels
B Danger—Flowing grain traps and suffocates 1002313 2 See Bin Warning Labels
C Danger—Electrocution Hazard 1002314 2 See Bin Warning Labels
FRENCH WARNING LABELS TO BE PLACED ON EQUIPMENT
ADanger—Rotating Augers 1002312 AS
REQD See Equipment Warning Labels
D Danger—Rotating Pulley 035695 AS
REQD See Equipment Warning Labels
E Warning—High Voltage 035698 3 See Equipment Warning Labels
FRENCH WARNING LABEL IDENTIFICATION
10

A. Danger—Rotating Augers
C. Danger—Electrocution Hazard
B. Danger—Flowing Grain D. Danger—Rotating Pulley
E. Warning—High Voltage
PLACED ON BIN:
A. Danger—Rotating Augers
PLACED ON EQUIPMENT:
11

BDanger—Flowing Grain
ADanger—Rotating Augers
CDanger—Electrocution Hazard
Labels Applied to
Man Hatch Door:
BDanger—Flowing Grain
ADanger—Rotating Augers
CDanger—Electrocution Hazard
Labels Applied Outside Bin Door:
Apply labels at eye level on the same side as latch
Bin Warning Labels
Bin warning labels to be added during equipment installation:
• Two sets of Warning Labels (A, B, & C) are provided for placement on the bin.
• Check that all labels are present and legible each season - contact your local dealer for
FREE replacements if any are missing or damaged.
• Make sure the surface is free of oils, dirt and moisture.
• Apply labels as shown
NOTE: If the bin has a double man-hatch door, afx the label to the inside of the outer door or
to the outside of the inner door.
Each season, check to make sure all warning labels are present and legible !!
Contact NECO customer service for free replacements @ [phone]
12

Equipment Warning Labels
• DOMESTIC warning labels A, D, & E are applied at the factory.
• FRENCH warning labels A, D, & E are applied in the eld - make sure the surface is free of
oils, dirt and moisture and apply labels in the locations shown below:
LABEL “A”
(ON EACH TROLLEY)
LABEL “E”
(ON ALL ELECTRICAL BOX COVERS)
LABEL “D”
(ON EACH TROLLEY BELT GUARD)
Each season, check to make sure all warning labels are present and legible !!
Contact NECO customer service for free replacements @ [phone]
13

3. EQUIPMENT OVERVIEW
EQUIPMENT DESCRIPTION
The NECO supplied SMARTstir system is a simple, rugged, and reliable grain stirring machine.
Some of the included features are:
• Patent Pending Down Auger Protection System (DAPS)
• Modular Design
• Moisture Resistant Electrical Junction Boxes
• Rotating Contactor With Safety System
• Main Support Beam With Fill-Hatch Hanger System
• Gear Motor Drive
• Circular Track System With Brackets
NOTES
• Because the stirring machine auger runs close to the bin wall, no inside wall ladder can be
used. A portable ladder is advised and can be obtained from your dealer.
• If the SMARTstir system is included with a new bin install package, see “TURNKEY INSTALL
FOR A NEW BIN”.
• Make sure there are enough roof openings to let the air ow freely and to let moisture
escape. SEE IMPORTANT INFORMATION BELOW
WARNING
INSUFFICIENT AIR EXHAUST AREA MAY RESULT IN DAMAGE TO YOUR BIN
• Proper aeration or drying exhaust air openings must be provided in the form of roof
vents or open manholes when the bin fan is operating.
• A suggested minimum of 1 square foot [.09 square meters] opening for EACH 1,000
cubic feeet per minute [30 cubic meters per minute] of air.
• Before running the equipment, the operator must be sure that these openings are not
constricted by chaff, ice, or other materials during fan operation.
14

ASSEMBLED LAYOUT WITHIN BIN
15
8 7/8”
CENTER
OF TRACK
EAVE
ALLOW 4” FOR CLEARANCE ABOVE “HIGH POINT”
HIGH POINT = • FOR BINS WITH EQUIPMENT SUCH
AS SWEEPS, ETC. THE HIGH POINT IS MAXIMUM CLEARANCE TO CLEAR THE OBSTRUCTION.
• FOR BINS WITH NO EQUIPMENT ON
THE DRYING FLOOR, CONSIDER THE FLOOR ITSELF AS THE HIGH POINT.
MAX. FILL HEIGHT
18”
THE BEAM SHOULD HAVE 1/8” PER FOOT RISE
FROM THE BEAM HEIGHT AT THE TRACK.
CONCRETE PAD
HIGH POINT
PLENUM AREA
BIN FLOOR
87
8" MINIMUM
TRACK C/L

STANDARD COMPONENT ID
HANGER CHANNEL
ASSEMBLY &
CENTER PIVOT
DOWN AUGER
CARRIAGE ASSEMBLY
BELT
SHIELD
DRIVE
CLUSTER
MAIN
BEAM
TROLLEY
JUNCTION BOX
MAIN
JUNCTION
BOX
DOWN AUGER
OR
STIRRING AUGER
PITMAN
ARM
&
DRAFT
LINK
SPACER
BRACKET
TROLLEY
WHEELS
2X
CARRIAGE FRAME
DETAIL
TROLLEY
DRIVE
SPROCKET
16
DO NOT remove the bolts securing the trolley drive
gear to the shaft. EQUIPMENT WILL DROP !!!!
DANGER
See MAINTENANCE section for details.

ROTATING
CONTACTOR
DAPS SPRING
2X
DRIVE
CHAIN
TENSIONER
DRIVE
CHAIN
POWER ENTRY
JUNCTION BOX
(2X) FESTOON
BRACKET & CABLE
CORD
CARRIER
SIX
CORD
SUPPORT RINGS
DAPS
SWITCH
FLANGE
BEARING
2X
SHOWN WITH DRIVE BELT
& BELT SHIELD REMOVED:
AUGER
DRIVE
MOTOR
AUGER
DRIVE BELT
TENSION SPRING
TROLLEY
FRAME
PIVOT ROD
17

4. ASSEMBLY & INSTALLATION
TURNKEY INSTALL FOR A NEW BIN
Installation requirements vary per individual needs, but in general the following steps represent
a turnkey situation where the SMARTstir is being installed as the bin is being erected:
• Assemble top ring of the bin wall per manufacturer’s instructions.
• Depending upon wall ring height, a second wall ring may need to be installed so that installing
the track can be completed at a comfortable working height.
• Assemble the roof to the top ring.
• Afx man hatch safety labels on the roof’s man hatch door.
• Determine the correct track distance below the eave line and complete the track installation.
• Mount the main disconnect switch.
• Install the hanger brackets & chains.
• Complete the SMARTstir assembly - follow instructions using beam supports and secured with
clamps up to the level of having the assembly able to be positioned onto the track, position
the unit with the correct slope toward the bin center, and connect the hanger chains.
• Continue with bin assembly - the stirring system rises with the structure.
18

GATHER TOOLS, ID COMPONENTS, MISC ITEMS
Before bin assembly, do the following:
• Locate a pair of sawhorses or similar supports to assemble the beam section on.
• Determine if there are any special considerations, such as grain spreaders or sweep
augers that may require different positioning of the track and stirring equipment.
• Because the auger system runs close to the bin wall, no inside wall ladder can be used.
A portable ladder is advised and can be obtained from your dealer.
• The following table shows abbreviations used throughout the manual for hardware items:
• Gather, identify, and sort the all parts in the center of the concrete pad for ease of
accessibility.
• The following tables show the assembly parts included with the SMARTstir system when
shipped. Also shown is “where used” for most parts, with the exception of bulk hardware
fasteners such as bolts, washers, and nuts.
• Each assembly step identies the NECO part numbers involved and also lists the required
hardware needed to secure the assembly or part.
ASSEMBLY HARDWARE KEY
KEY ITEM DESCRIPTION
HB HEX BOLT
CB CARRIAGE BOLT
FW FLAT WASHER
LW LOCK WASHER
HN HEX NUT
FN FLANGED NUT (WHIZLOCK)
NOTE: Unless otherwise specied, standard
assembly hardware should be zinc plated and
minimum Grade 5. Tighten all connections rmly.
19

ASSEMBLY PARTS I.D.
#038418 - BOX OF PARTS (COMMON)
PART # QTY ITEM DESCRIPTION WHERE USED
002073 28
FT CABLE AIRCRAFT 7X19 3/16” ATTACHED TO FESTOON BRKTS
030062 2 FESTOON CABLE BRKT AT EACH END OF MAIN BEAM
030109 1 PITMAN ARM SUB-ASSY ON TROLLEY CLOSEST TO CENTER
030119 1 JCT BOX ELECTRICAL INLET ON TOP OF CENTER HANGER
030123 1 MANUAL - SMARTstir OWNER - OPERATOR MANUAL
038417 1 BOX OF HARDWARE - COMMON SEE “BOH” TABLE
038968 3 CHAIN HANGER BRACKET MOUNTS TO PEAK RING
039377 3 CHAIN 1/4 X 12’ W/S-HOOK ZINC CHAIN FROM PEAK HANGER
039567 1 MOUNTING PLT DISCONNECT TO MOUNT ELECTRICAL
DISCONNECT ON BIN ROOF
039828 1 CHAIN 1/0 DOUBLE LOOP X 33’ SAFETY CHAIN FROM DISCONNECT
039919 1 DRIVE CLUSTER ASSEMBLY ON MAIN BEAM - TRACK END
039954 1 CENTER HANGER ASSY ON MAIN BEAM - BIN CENTER END
039973 1 DRIVE CHAIN IDLER ASSY BOTTOM OF MAIN BEAM
039976 3 HANGER CHANNEL LEG ATTACH TO CENTER PIVOT ASSY
039984 1 DR CHAIN TENSIONER ASSY BOTTOM OF MAIN BEAM
7715529 1 PIPE NIPPLE 1” X 2” SCH40 ATTACH ELEC ENTRY BOX AT TOP
OF CENTER PIVOT
EACH SMARTstir SYSTEM HAS THIS BOX OF PARTS:
Trolley System Drive Chain
Bin
Dia
2
Trolley
3
Trolley
4
Trolley
24’ 039853
-- --
27’ 039855 030450 --
30’ 030453 030451 --
33’ 030455 039853 --
36’ 030456 039855 030450
40’
-- 030454 030452
42’
-- 030455 039853
48’
-- 030457 039854
TROLLEY SPACER
BRACKET(S)
PART # # OF
TROLLEYS QTY
039975
2 1
3 2
4 3
EACH SMARTstir SYSTEM HAS ONE: QTY BASED ON # OF DOWN AUGERS:
20