F-SERIES MECH SEAL 1/04
Contents
1. 13 4 Remove the four 3 8 bolts mounting the motor to the spool and then the two may be separated 13 5 Bearing and seal removal Place the mixer spool ina bench press with the motor mounting face SIANDARD DIRECT DRIVE IM PELLERS 6 CAT MARINE PROPELLER FMSSM 7 04 11 down Use a 1 1 2 diameter arborin the presson top ofthe lip seal and pressthe lip seal and the bearing down and out of the spool 13 6 Reinstall the bearing from the inside of the spool using a LOCTITE sealant 609 or better to hold the bearing in place The lip seal must be installed from the outside of the spool into position as shown in the drawing 13 7 To reassemble reverse procedure being sure thatthe shaft hasfull engagement in the split cou pling and all fasteners are tight forside entry units a gap of 1 16 must be maintained between the seal collar gasket 675 and the flange HIG H SHEAR DIRECT DRIVE F SERIES E Veg em gt ES 100 651 e ds Z Z C L 612 adi 512 510 ale 650 zi RN F UL UL 301 673 672 SEE SEAL DETAIL IN FRONT OF N THIS MANUAL FOR EXACT SEAL 552 DESCRIPTION AND PARTS LIST 600 Wi 100 MO2. 1 1 For split mechanical seals follow instructions in sec 3 2 and bolt sealin place after shaft installation See end of manual for any special instructions 3 1 2 Forall other mechanical seals install shaft through flange orferrule Use a light oil to aid in installation of seal Slide seal partsonto shaft in order according to the drawingsin front of manual and any seal instructionsat end of manual 3 2 Remove the service window from the mixer spool so the bearing and coupling are visible see page 12 or 13 Rotate the coupling until the two coupling bolts are accessible Install the mixer shaft with the end marked_motor end up through the lip seal 360 bearing 301 and into the drive coupling 650 Be sure of fullengagement of the shaft into the split coupling DO NOTuse oil to aid in assembly or dippage may occur Using the 3 16 hex wrench supplied TIGHTEN THE TWO BOLTS IN THE JI COUPLING 651 gripping the mixer shaft in position Tighten SEC URELY as these bolts transmit the mixer torque TIGHTEN THE TWO BEARING SET SCREWS 310 SI using the 1 8 hex wrench provided Fasten seal setscrews and bolts SECTION 4 POSITIONING 4 1 The following drawingsare for reference only If there isany question conceming the proper position of your F series mixer please contact your 4 2 If tank diameter is approxi mately equal to liquid depth use 1 prop placed atleast 2 prop diameters from the bottom of the t
3. all bearings seals gears when applicable and otherrecommended spare parts asshown on pages 12 and 13 of this manual motor optional Call Sharpe Mixers for current prices FMSSM 7 04
4. amps Lack of orimproper Fill with recommended lubrication lubricant or equivalent see Section 7 Start stop start loading Free impellerof any solids at product burying start up pre stir with air impeller with solids hose or paddle Foreign material in lubricant Replace lubricant Oilleakage Excessive lubricant Check manualforproper amount lubricant and drain excess Damaged broken gasket Replace gasket Loose bolts around Checkand tighten bolts side plates Seals wom or Replace seals damaged Sealleakage Wom mechanical seal Replace seal Damaged mating ring Replace mating ring e Solids in seal gland e Flush properly see Section 9 Scored shaft Replace shaft and seal lubricate flush seal e Insufficient inc orrect lubrication Lubricate properly see Section 9 Excessive heat Lubricate properly or consult factory a special seal may be required eIncorect seal position See drawings in front of manual forcormect position FMSSM 7 04 17 Notes AIR RLIER REGULATOR LUBRICATOR An airfilter regulator and lubricator must be used with air drive portable mixers If your system already hasa filter regulator and lubricator a needle valve isused formotorspeed adjustment These are available from Sharpe Mixers SECTION 17 ACCESSORIES 18 A Mixer Fixer Kit is available for rebuilding your Sharpe Mixers portable mixer This kit includes
5. as customers applications Listed below are some typical application designs Study the seal drawing and description in this manual and circle the lubrica tion system that best describes your application Reservoirs filters rota meters flow and pressure control valvesand gaugesasrequired may be purcha sed from Sharpe Mixers 9 3 SINGLE INTERNALLY MOUNTED SEAL This design hasthe rotating elements of the seal in contact with the tank contents and islubricated by one of the following means 9 3 1 Lubricant flushing requiresa line of compat ible lubricant usually water plumbed to the housing ata higher pressure than the tank Thisallowsa constant flushing of cleansing lubricant through the seal housing and into the tank It isrecommended that a flow control valve pressure gauge and rota meter be installed in that orderon the line to the seal 9 3 2 Lubricated by tank contents this system for side entry only requiresthe tank contentsto have lubricating properties and to be clean of any solids Any suspended solids or dissolved solids that may crystallize will build up in the seal housing and cause premature seal leakage 9 3 3 The plugsin the seal housing need to be replaced by permanent stainless steel plugs if not fumished After filling tank bleed all gasestrapped in the seal housing or vaporlock may ruin the seal If flushing is not used periodic bleeding of the seal cavity will cleanse the solids buildup and ex
6. may be damaged due to weather A rain hood orother protection may be necessary to prolong motorlife Consult factory for recommendations 10 8 Check mixer dra wing and Data Sheet for special operating requirements when using a vari able speed drive or air motor when supplied by Burhans Sharpe Co 10 9 Do not drive air motorsabove 1750 R P M See Table 10 1 or 10 2 forproperairconsumption and pressures The motor size is specified in motor data of the Data Sheet 10 10 Regular maintenance isthe best assurance of trouble free long life mixer operation Inspect and lubricate at regularintervals Frequency and thor oughness dependson operation nature of service and environment 6AM AIR MOTOR 1750 MAXIMUM R P M H P 0 5 0 5 1 0 ae 2 6 C F M 23 39 53 68 82 P S I 20 40 60 80 100 TABLE 10 2 10 11 StartUp Checklist Priorand during start up please check that the following thingshave been done a Manualhasbeen read and followed E b Coupling boltstight 3 16 hex tee wrench c Bearing setscrewstight 1 8 hexallen wrench E d Impeller is immersed in liquid E e Sufficient protection of motor if outdoors f Impeller s installed correctly see Section 3 E g Impellersspaced correctly if two or more for maximum and minimum liquid level see Section 3 h Impeller bolts tight i All mounting bolts tight E j Propertype and amount
7. next size pipe size largerthan intake port of motor A regulatorcan be used to govem the mixer speed Install the airline in the proper port to provide clockwise rotation of the propeller shaft when viewed from above The muffler is always installed at the factory in its properposition WARNING Damage to equipment or serious injury to personnel can result if speed limitations are not followed SECTION 7 LUBRICATION 6 1 Yourmixer hasbeen lubricated at the factory with the propertype and amount of lubrication for mixer service geardrive unitsonly Thislubricant needn tbe changed under nomal conditions for a period of 3 years Underextreme conditions it is recommended thatthe lubricant in the gearboxbe SERVICE LUBRICANT changed more frequently Remove motorto repack gearbox Referto the chart below forthe lubricant recommended fortemperatures in your area When changing to a different lubricant clean gearbox with mineral spirits before repacking CHEVRON EQUIVALENT 32 F 0 C and up Down to 20 F 29 C and up to 300 F 149 C Food grade 6 2 Electric motor bearings are usually sealed and need no relubrication If zirc fittings are present relubricate with a No 2 consistency lithium soap base and petroleum compound every 6 monthsto 3 years depending on usage Open and clean drains Add grease until new grease isforced out drain Remove excess grease and replace input plugs Run motor one
8. of lubricant E when serviced see Section 7 k Wiring correctly installed grounded and insulated Proper shaft rotation clockwise looking down E m Propermechanical seal lubric ation flushing M n Comectvoltage amperage upon starting check against motor nameplate data Record Volts amps O Excessive noise after start up Record db 3 p Excessive vibration of mixer support q Steady bearing installed correctly see Section 5 INSPECTOR DATE Notes 8 FMSSM 7 04 SECTION 11 SIDE ENTRY RETRACTION 11 1 This section s instructions are to seal off tank contents for replacing the mechanical seal without removing the mixer from a tank full of liquid This is for side entry mixers supplied with the shaft retraction feature only 11 2 Disconnect the power from the mixer 11 3 Remove the service window Loosen the two bearing setscrews and the two lower coupling bolts Do not loosen the two coupling boltsclosest to the motor Do not remove any of the setscrews 11 4 Remove the two retraction bolts 673 insta lled in the bearing spool Move the retraction collar 672 to within an inch of the bearing spool Tighten the collar on the shaft lining up the drilled holes in the collar with the tapped holesin the bearing spool Reinstall the two boltsthrough the holes in the retraction collarand into the tapped holes in the spool Tightening these retraction bolts will pull the retraction collarand mixershaft in a direc
9. the lower impeller immersed in the liquid by atleast one prop diameter Neveroperate mixer if fluid falls below this level 10 3 Neveroperate mixer without the mechanical seallubricated see Sections 8 amp 9 Dry running seals are the exception 10 4 The propeller rotates cloc kwise when viewed from above Opposite rotation may cause overload and inefficient mixing 10 5 Vortexing may occurif liquid level istoo close to the upperimpeller This will cause aeration of the product and excessive vibration of the equipment When mixing products of dissimilar viscosities and or specific gravitiesthe lighter or less viscous material must be introduced first Gradually add the heavier material or powders into the centerof the tank while the agitatorisrunning Neverdump large amounts of powder or solids into the mixing tank This may create clotting or sanding in of impellerand cause damage to the equipment 4AM AIR MOTOR Q 1750 MAXIMUM R P M H P 0 25 0 5 0 75 1 0 1 2 C F M 14 22 30 39 48 P S I 20 40 60 80 100 TABLE 10 1 FMSSM 7 04 10 6 If impeller is buried in solids prior to starting mixer solids must be dispersed This may be achieved with an air hose a recirculating pump ora large stirring sic k if necessary 10 7 Keep motorsfree from oil dust dirt water and chemicals Keep airintakesand outletsfree from foreign material Electric motors supplied although designed foroutdooruse
10. the seal detail drawing in front of this manual to set the correct distance 12 17 Tighten all seal sets rews when present Do not over tighten setscrews Seal setscrewshave a cupped point which is easily dulled after repeated use Replace setscrews after two or three installa tions Overtightening the seal mounting plate gland plate may cause warpage of the seats Finger tighten each bolt until housing isseated square Further tighten each bolt 1 2 3 4 tum in an opposite diagonal sequence to guarantee even pressure on the seal housing gasket The alignment squareness of the gland plate with respect to the flange and shaft needsto be checked with a feelergauge to prevent uneven wear on the stationary seats and primary rings 12 18 Tighten the two coupling bolts 651 Tighten the two bearing setscrews 310 Replace the service window and gasket The mixeris now ready forservice See section 8 and 9 forseal start up and operation 12 19 Asalways should you have further questions please feel free to contact your Sharpe Mixers representative or call the main office forassistance FMSSM 7 04 SECTION 13 DIRECT DRIVE DISASSEMBLY 13 1 Disconnect power from the mixer 13 2 Rebuilding the drive unit isaccomplished by removing the entire mixer from the tank Remove the impeller from the shaft before removing the mixer from the mounting flange 13 3 Be sure that Section 12 1 through 12 15 has been accomplished
11. BEARING 810 2 S S BRASS TIPPED SET SCREWS 360 SHAFT LIP SEAL 510 BEARING SPOOL 512 SERVICE WINDOW 513 SERVICE WINDOW GASKET 600 MIXER SHAFT 650 COUPLING 651 4 SPLIT COUPLING BOLTS NOTE WHEN ORDERING PARTS GIVE SERIAL NO AND SHAFT SIZE L DENOTES RECOMMENDED SPARE PART SECTION 14 GEAR DRIVE DISASSEMBLY 14 1 Disconnect power from the mixer 14 2 Rebuilding the drive unit isaccomplished by removing the entire mixer from the tank Remove the impeller from the shaft before removing the mixer from the mounting flange 14 3 Be sure that Section 12 1 through 12 15 has been accomplished 14 4 Remove the three motorbolts and the motor may be lifted off the gearhead assembly Remove the four 4 3 8 gearhead assembly bolts and lift off the gearbox housing 203 The bearing plate may now be removed with the gear gearshaft and coupling assembled Clean the assembly of grease and rinse with mineral spirits Handling the gear shaft subassembly is best accomplished using a piece of round barthe same diameterasthe mixer shaft Clamp the round barin a bench vise and tighten the drive coupling onto the round bar If a round barisnot available clamp the coupling in the vise using two pieces of wood so asnotto damage the coupling To remove the gearnut first bend down the locking tab on the star washerfrom the slot in the gearnut Using a spanner wrench loosen the gear nut from the shaft Remove t
12. ING GUIDE POSSIBLE C AUSE Wrong end of shaft only one end fits 2 bearing set screws extend into bearing bore 2 coupling bolts too tight e Shaft over size properdia 0 001 0 002 under nominal dia Wrong size shaft coupling or bearing Damaged shaft coupling or bearing SOLUTION Install end marked motor end eLoosen set screws Loosen bolts Measure and consult factory Consult factory Consult factory e Mixer will not start Incorrect wiring oose connections e Blown fuse Incorrect voltage Mechanical jamming Water damage to motor Wrong size heaters in starter Check wiring diagram and wire correctly Check and tighten connections Replace fuse Wire for correct voltage Free all debrisforrotation Service orreplace motor Replace heaters e Mixer will not reach conect Overload of motor eCheck amperage against nameplate data speed Loose drive coupling bolts 651 Check coupling bolt tension coupling and or shaft maybe damaged if mixerhas been run with slip ping coupling e Air motor vanes ports dirty Flush air motor with non combustible solvent relubricate e Insufficient pressure for air motor Increase airline compressor size decrease compressor distance from air motor See all items under Mixer will not sta rt Motorruns hot Low orhigh voltage Wire for correct voltage Amperage overload Product too viscous e
13. ITH NATURAL CONVECTION LUBRICANT RESERVOIR This design requires a lubricant reservoir usually 2 5 gallon capacity mounted 6 18 above and no more than 3 ft away from the mechanical seal These systems are often fumished by Burhans Sharpe mounted on the agitatorand fully plumbed to the seal housing Lubricant circulation occurs when the lubricating fluid heated by the seal expandsand becomes lighter and rises out of the seal to the top of the lubricant reservoir Once in the reservoir the fluid cools becoming heavierand retumsto the mechani cal seal housing Natural convection requires low restriction plumbing asfollows Use large diameter FMSSM 7 04 tubing 1 2 recommended from the uppermost port in the seal housing to the upper liquid level in the lubricant reservoir The retum line runs from the bottom of the reservoir to the lower port in the seal housing Keep horizontal runsto a minimum 9 6 1 Fillthe seal reservoir until liquid level is higher than uppermost plumbing line Recheck level after mixer has run a few minutes and replenish if neces sary Operating liquid must be thin waterlike since thicker materials will not flow creating heat buildup and premature seal failure If tank is pressurized maintain 15 30 psi above tank pressure in the lubricant reservoir Thisisaccomplished by eithera permanent air line to the top of the reservoir with a pressure regulating valve a nitrogen tank orother compatible pressurize
14. N 17 ACCESSORIES rte oerte nd A ds d denn de a rnc 18 CAUTION Because neither manufacturer norseller can control the application or installa tion of this product their only obligation shall be to replace this part if defective and shall not be liable forany injury loss ordamage direct orconsequential arising from the installation of this product Userassumes all risk in using this product and istherefore cautioned in selecting the product suitable to the intended use Referto inside cover of this manual for Terms and Conditions SECTION 1 INITIAL INSPECTION RECEIVING AND STORAGE 1 1 Immediately upon receipt of the equipment check the crating and contents for any damage that may have occured in transit Report any damage immediately to the carrier and to Sharpe Mixers Check against the packing slip to be sure that all parts were received Report missing itemsto Sharpe Mixers 1 2 Mixerand impellers are normally packed to gether The mixer shaft is packed in a separate container Impellers are usually banded to mixer drive orlag bolted to drive skid Side entry mixersare normally shipped on one skid with the shaft installed and the impeller lag bolted to the skid If space allows keep shipping containersfor possible future use 1 3 Storage storage is when a mixerhasbeen deivered to job site and isawaiting installation b FMSSM 7 04 mixer has been installed but regular operation is delayed c the
15. OPERATION angl MAINTENANCE E INSTRUC WONS f r SHARPE MIXERS LO SED TANK Fs SERIES MIXERS with MEC SEALS TABLE OF CONTENTS PAGE SECTION 1 INITIAL INSPEC TIO N RECEIVING 1 SECTION 2 MOUNTING ier erred p aa o OE n ed 2 SECTION 3 INSTALLING THE MIXER SHAFT amp 2 SECTON 4 POSITONING ient rr moa fe unu reds Ga Ra edente qapay Pr 2 SECTION 5 INSTALLING THE STEADY BEARING optional equipment 3 SECTION 6 MOTORCONNEC TIO NS rp cio Fon E ee dece 4 SECTION 7 TUBRICATION IL uu na nnne 4 SECTION 8 MECHANICAL SEAL PREPARATION n a 5 SECTION 9 MECHANICAL SEAL LUBRIC ATIO N eene 6 SECTION 10 OPERATION START UP C HECKLIST esee 7 SECTION 11 SIDE ENTRY RETRAC TIO N ssseeeseeeeneeeneneennen nennen nnne nennen nnns 9 SECTION 12 MECHANICAL SEAL 10 SECTION 13 DIRECT DRIVE DISASSEM BLY seeeeeeeenenen nennen nennen 11 SECTION 14 GEAR DRIVE DISASSEMBLY nitet d e E 14 SECTION 15 MIXER OFFSET GUIDE eene nennen nnne nennen nens 15 SECTION 16 TROUBLE SHOOTING 16 SECTIO
16. Restricted ventilation Frequent starting and stopping Unbalanced voltage between phases eIncorect rotation Air motornot properly lubricated 16 Contact factory Check viscosity and specific gravity of product consult factory Clear vents Check with factory a special motor may be required Consult electrician Change motor leads per nameplate instructions Lubricate see Section 7 FMSSM 7 04 PROBLEM POSSIBLE C AUSE SOLUTION Shaft vibration e Impeller not immersed in liquid e Fill tank Impeller too close to surface e Fill tank or lower impeller see section 3 Bent mixer shaft Consult factory Unstable mounting platform e Reinforce platform Operating at critical speed Consult factory Noisy eCheck and tighten coupling Loose drive coupling bolts 651 orbearing set screws 310 e Insufficient lub ric a nt Foreign material in lubricant Incorrect lubricant Wom orfaulty bearings gears Dry lip seal in spool bolts and set screws Fill properamount of lubricant Change lubricant Change to correct lubricant Check bearings gears replace if necessary Apply lubricant to lip seal e Bearing failure High temperature product Excessive overhung load Waterdamage See all items under Noisy Provide heat shield Consult factory Replace bearing check all other parts Gearfailure e Excessive loading Consult factory check
17. TOR 301 SPOOL BEARING 305 NI GRAPHALLOY BUSHING NOT SHOWN r 310 2 S S BRASS TIPPED SETSCREWS 360 SPOOL LIP SEAL 400 MECHANICAL SEAL ASSEMBLY NOTE WHEN ORDERING PARTS GIVE SERIAL NO AND SHAFT SIZE L pENOTES RECOMMENDED SPARE PART 12 510 BEARING SPOOL 512 SERVICE WINDOW 513 SERVICE WINDOW GASKET 552 MOUNTING FLANGE HO USING 600 MIXER SHAFT 650 COUPLING 651 4 SPLITCOUPLING BOLTS 672 RETRACTION COLLAR SIDE ENTRY ONLY 673 REIRACTION BOLT SIDE ENTRY ONLY 674 SEAL COLLAR SIDE ENTRY ONLY 675 SEAL COLLAR GASKET SIDE ENTRY ONLY 750 IMPELLER SEE OPPOSITE PAGE FMSSM 7 04 GEAR DRIVE F SERIES CDEN 233 232 I J ea gw Wh 230 Eu RO CIES ow aue T 201 ATA IWAN P gt 221 h e 223 Z lt 9 512 7 813 AN 310 901 A RN 360 100 MOTOR 104 PINION GEAR KEY 118 C FACE GASKET 201 BEARING PLATE 203 GEAR HOUSING t 204 PINION GEAR 205 HELICAL GEAR 211 GEAR SHAFT 221 GEARBOX BEARING 223 GEARBOX LIP SEAL 227 GEARBOX GASKET 230 BEARING RETAINER FMSSM 7 04 13 300 P y 18 203 a JL 204 227 510 650 651 231 GEAR SPACER RING 232 STAR WASHER 233 GEAR NUT 301 SHAFT
18. a broad term intended to coverthe problem of sealing against slurries congealing liquids crystal lizing salts and the like They cause the greatest FMSSM 7 04 damage to equipment and present difficultiesfor mechanical seals In general the cure involves flushes purges and temperature controls See mechanical seal lubrication Section 9 for more information on lubrication and flushing of mechanical seals 8 6 1 SUSPENDED SOLIDS Solids which are suspended in liquids and which are an inherent part of their structure would include starch contaminated or muddy water sand and other slumies This is best handled by an extemal flush of clean liquid through a lantem ring Flushing pressure needsto be 15 30 psi greaterthan tank pressure 8 6 2 PRECIPITATING LIQUIDS Solids which precipi tate out of a liquid do so by reason of eitheran increase in concentration orbecause of a lowering orin some casesa raising of temperature beyond that at which it is properto operate Illustrations are caustic soda and calcium hydroxide With ammo nium nitrate for example temperature must be controlled at an optimum level in relation to its concentration If the temperature risesabove the optimum it will boil and form crystals and conversely if temperature drops it will become saturated and salt out 8 6 3 EVAPORATING LIQUIDS Solids can form asa result of heat which promotes evaporation Ex amples include any of the hot chemical
19. above mechanical seal so asno damage can occurto the seal during removal Clean parts using a clean soft cloth and a light oil Inspect forwearand damage replace if necessary 11 13 Locate the mechanical seal seat see seal detail drawing in front of manual Checkfordam age and wear Replace if necessary including gaskets 11 14 If the drive unit needsto be rebuilt it is best done atthistime See Section 13 or 14 11 15 To reassemble reverse procedure Make sure the mechanical seal isin the exact same position as when disassembled 11 16 Use a light lubricant to aid in reinstallation of the mechanical seal Be sure the seal partsare in the correct position especially the facesof the seat and seal See applicable seal drawing in the front of this manual Install the shiny face of the seat facing the rotating seal 11 17 Tighten all seal setscrews when present Do not overtighten setscrews Seal setscrewshave a cupped point which is easily dulled afterrepeated use Replace setscrewsaftertwo orthree installa tions Overtightening the seal housng mounting plate may cause warpage ofthe seats Finger tighten each bolt until housing is seated square Furthertighten each bolt 1 2 3 4 tum in an opposte diagonalsequence to guarantee even pressure on the seal housing gasket The alignment squareness ofthe gland plate with respectto the flange and shaft needsto be checked with a feelergauge to prevent uneven wearon the stationa
20. ank 43 See drawing A2787insection 4 4 15 for angular offset mounting dimensions Consult factory for special applications including square rectangular tanks Sharpe Mixers representative orthe factory as your specific application may be different than recom mendations shown If tank height is greater than 1 5x the diameter use 2 props Position lower prop at least 2 prop diameters from bottom Place upper prop halfway between bottom and top of liquid level FMSSM 7 04 4 5 Fordrawing down light powders position mixer in center of tank to create a vortex A vortex may not be recommended forsome products Depth of prop will vary vortex 4 6 Bafflesmay be used to prevent vortexing when mixer is mounted on center Baffling may not be required with more viscous productsorsquare rectangular tanks SECTION 5 INSTALLING THE STEADY BEARING optional equipment 5 1 This section is for those mixers which include the optional steady bearing to accommodate longer than standard mixer shafts A steady bearing must be installed only after the drive assembly and lower mixer shaft have been assembled and firmly bolted in place DO NOTpredetermine the exact bearing location from tank and mixer outline dimension drawings The vertical centerline of the steady bearing must coincide with the shaft s axis of rotation to minimize bearing preload see Figure 5 1 Thisaxis may not necessarily be atthe centerof the tank The mi
21. d medium A back pressure valve may be incorporated to prevent the back flow of tank contents in case of seal failure during a loss of pressure in the supply system A low pressure shut off switch may also be used to shut down the mixer in case of a seal system failure 9 6 2 Many lubrication reservoirs incorporate cooling Coils to further remove heat from the lubricating fluid on high temperature applications Otherlines may also be required to coolthe seal housing orflange These will be shown in the seal assembly drawing Cooling water must circulate at all times when heat is present 9 6 3 A 10 weight oil or other thin noncorrnosive lubricating liquid is recommended ratherthan water when the lubrication reservoir is carbon steel 9 7 DOUBLE MECHANIC AL SEAL WITH POSITIVE FLOW LUBRICATION SYSTEM This system utilizes a remote lubricant reservoir with a pump supplying positive flow to and from the seal often with a cooling system pressure and flow control valves low level alarms and other integrated systems which require thorough study and preparation priorto start up period It is recommended that you contactthe appropriate mechanical seal representative in your area for assistance with any questions you may have on the more intricate systems SECTION 10 OPERATION 10 1 Rotate mixer shaft by hand to check shaft straightnessto assure that the impellerisfree of any obstructions in the tank 10 2 Neveroperate mixer without
22. eeth If replacing both the motorand pinion gear Sharpe Mixers will normally supply the motor with the pinion gear installed Pack the gearboxfull with the appropriate lubricant see Section 7 Alwaysreference mixer serial number when making a parts inquiry or placing an order This serial number is located on the Sharpe Mixernameplate and on the front coverof the service manual TN HYFLO Il ENERGY EFFICIENTIM PELLERS ARE SIANDARD ON GEAR DRIVE F SERIES MIXERS FMSSM 7 04 SECTION 15 MIXER OFFSET GUIDE IMPELLER ROTATION p 3 FLANGE MOUNTING LONG OFFSET LONG OFFSET O O o C e 9 6 NN C 9 Wut SHORT Q C OFFSET TANK CENTERLINE Y SHORT OFFSET 3NITH31N39 MNVL MOUNTING 9 16 HOLE 4 PLACES Dimensions are for reference only Use certified prints for construction Dimensions are in inches 1 REFER TO DATA SHEET FOR DIMENSIONS revision 1 7 20 04 JDH 2 MINIMUM MOUNTING CHANNEL REQUIRED TANK DIA UP TO 96 4 x 7 25 TANK DIA OVER 96 6 8 2 83 OFFSET DIMENSIONS ARE TO CENTERLINES ON TOP OF FLANGE TANK DETAIL FOR ANGULAR OFFSET PLATE MOUNTING FMSSM 7 04 15 TANK MNT ANGLE OFFSET S by KWS 11 97 PROBLEM e Shaft will not fit into drive SECTION 16 TROUBLE SHOOT
23. en stock a limited supply of the partic ular style you may require 12 2 When replacing mechanical seals it is important to protect the sealfaces Alwaysclean and deburr any sharp edges nicks or burs in the shaft prior to reinstalling the seal A light oil may be used to aid in assembly Measure compressed seal height priorto disassembling and match this height at reassembly 12 3 Disconnect the power from the mixer Replac ing the mechanical seal isaccomplished by remov ing the entire mixer from the tank with the exception of split mechanical seals For split seals referto the end of the manual for seal specific instructions 12 4 Remove all flushing or lubrication lines from the mechanical seal housing orgland plate when present 12 5 Remove the impellerfrom the shaft before removing the mixer from the mounting flange Remove the mixer from the mounting flange Do not remove the shaft at this time For mixers with the mechanical seal mounted on the tank side of the mounting flange see paragraph 9 3 4 and a backup packed gland feature skip to paragraph 12 9 12 6 Remove seal mounting bolts 413 Move seal housing towardsthe bearing spool For inside mounted seals MARK THE SHAFT AT THE SEAL FOR REPOSITIONING 12 7 Loosen the seal setscrews orcollar if appli cable 12 8 Slide the mechanical seal towards the bearing spool 12 9 Remove the service window 512 Loosen the two bearing setsc rews 310 and t
24. half hour before replaceing drain plugs Mixer shaft bearings are sealed and need no relubrication oil based EP Semi fluid grease Synthetic EP Food grade EP 2 Black Pearl NLGI 1 standard from factory ULTI PLEX synthetic grease EP Chevron FM grease EP2 6 3 Air motor lubrication Lubricator needsto be adjusted to feed one drop of oil for every 50 75 CFM of airthrough the motor Use a detergent SAE 10 automotive engine oil FMSSM 7 04 SECTION 8 MEC HANICAL SEAL PREPARATION 8 1 Mechanical seals are precision machined fragile components that are easily damaged by careless handling Any servicing of mechanical seal must be handled in a clean white coat manner Even a fingerprint on the mating sealfacescan cause premature leakage Most premature seal failures are due to lack of lubrication orimproper installation Seal manufacturers offer mechanical seal maintenance semina rs or seal schools to help service personnel understand seal operation better The minimal cost and time required forthis education is easily justified when you considerthe expense down time and lossof product which occurs when mechanical sealsfail prematurely 8 2 Do not even allow the mixerto be wired before preparing the sealforoperation The electrician may bump start to check for rotation and ruin the seal in the process Many double mechanical seals have assembly positioning tabs which hold the seal wear sleeve on center in position duri
25. he gearnut and the star washer The slow speed gear may be removed using a gear puller if it istoo tight to remove by hand Gearteeth are hardened and are easily chipped Use care when handling Loosen the uppertwo coupling bolts and remove the gear shaft bearing plate assembly from the coupling Place the subassembly in a press with the threaded end ofthe shaft pointing up Remove the spacerring 25 from the gearshaft Pressthe gearshaft 5 down out of the bearing plate Remove the four 1 4 cap screwsand the bearing retaining ring 230 Tum the bearing plate upside down so that the lip seal 223 ison top Using a 2 diameter arborpress the lip seal and the bearing out of the bearing plate See Section 13 4 for removal of bearing and lip seal in the spool 14 5 To remove pinion gear from the motor shaft first clean the pinion gearand motor shaft of grease Supportthe motor shaft with a soft block to prevent damage when removing the pinion gear The pinion gearmay be removed from the motor shaft using a gear puller Use care to not chip the teeth of the hardened gear Apply heatto breakthe adhesion of the Loctite 14 6 To reassemble a new gearon an existing motor clean all partsand trial fit the pinion gearon the shaft Never pound the pinion gearinto place Assemble gearand key flush with the end of the motor shaft using Loc tite amp zz RC 680 compound Remove any excess Loctite from the gear espe cially from the geart
26. he two lower coupling bolts 651 Do not loosen the two cou pling bolts closest to the motor Do not remove the setscrews Ifa packed gland backup seal is in cluded loosen the follower stud nuts 12 10 Remove the mixershaft CAUTION Take great care in removing the shaft Be sure shaft is debured and cleaned above mechanical seal so asno damage can occurto the seal when sliding the shaft through the seal 12 11 Locate the mechanical seal stationary seat see seal detail drawing in front of manual Check fordamage and wear Replace if necessary includ ing gaskets or o rings 12 12 Inspect mechanical seal fordamage and wear Replace if necessary 12 13 Replace seal housing o rings gaskets if appli cable 12 14 If bearing or bushing is present in the seal housing area inspect forwearand damage Re place if necessary 12 15 Rebuilding the drive unit is best accomplished at this point See Section 13 or 14 12 16 To reassemble reverse procedure using a light lubricant to aid in reinstallation of the mechanical seal Be sure the seal partsare in the correct position especially the faces of the seat and seal See applicable seal drawing in the front of this manual There must be fullengagement of the shaft into the split coupling 650 For side entry units 1 8 must be maintained between the seal collar and the mounting flange 552 orfor mixers with the packed gland backup seal use the dimension stated in
27. l manufacturer s instructions for proper connections and installation 6 2 Electrical connections must conform to National Electrical code and alllocal regulations Line voltage and wire capacity must match motorrating stamped on motor nameplate 6 3 Electric motors single phase If your mixer is supplied with a single phase motor it may be wired by the factory with a ten foot cord and an on off switch If no cord orswitch is provided referto the wiring diagram on the motor forcomect connec tions Checkthatthe switch is in the off position before plugging the cord into a 110 volt outlet Check rotation 6 4 Electric motors 3 phase Motorsrequiring 3 phase powershould be wired according to the wiring diagramson the motor Rotation of the propeller must be clockwise looking down Interchange lines if necessary for proper rotation 6 5 Hectric Variable Speed Electric motors using an SCR or variable frequency controller must be wired following the instructions supplied with the controller Many adjustments are often required to the controller and instructions should be read carefully before applying power Adjust the controllerto limit the maximum speed to the motornameplate R P M or referto the motorspeed in the data sheet atthe front of this manual 6 6 Air motors Air driven mixers must always have a filter lubricator and moisture trap installed in the air line ahead of the motorto prevent damage Use the same size or
28. ng shipping and assembly These tabsmust be rotated out ofthe way orremoved completely before start up 8 3 The mechanical seal housing orgland plate will have one or more tapped holes for lube vent drain which will be plugged from the factory with a tempo rary plastic plug These plugs must be replaced with the proper flush lube recirculating line or dead end plug asdescribed below under MECHANICAL SEAL LUBRIC ATION Section 9 8 4 Tank liquid level must be filled to at least one prop diameterabove the impellerelevation before starting mixer Mixer must never run when liquid level drops below this point A low liquid alarm or shut off switch is recommended if low liquid levels are likely to occur 8 5 Make sure all valves are open to insure the seal receivesa positive flow of liquid at alltimes Bleed all gases trapped in the seal cavity before start up or the cavity may vaporlock and the seal will bum up running dry On high speed above 350 rpm and high temperature applicationsthe mechanical seal housing must be constantly flushed with a cooling lubricant before applying powerto the mixer orheat will quic kly build and destroy the seal Where colder ambient temperatures will cause thickening of the lubricant the seal housing and lubricant lines must be preheated to allow free flowing lubricant to seal before start up Never allow the seal orlubrication linesto freeze 8 6 SEALING ABRASIVE LIQUIDS As used here abra sives is
29. re a flow restriction and pressure reducing valve must be incorporated in the supply line to the seal An in line filteris also recommended Neverallow pressure to build within the seal housing oryou may blowoutthe lip seal The drainage line must rise above the elevation of the seal housing by a few inchesto guarantee seal will be lubricated without siphoning and must be free flowing to prevent pressure buildup 9 4 2 Lubricated by tank contents side entry only this system requiresthe tank contentsto have lubri cating properties and to be clean of any solids Any suspended solids or dissolved solids that may crystal lize will build up in the seal housing and cause premature seal leakage 9 5 DOUBLE MECHANICAL SEAL WITH THROUGH FLUSHING This system requiresa lubricant line plumbed to the seal usually water and another line from the seal housing to the drain A flow control and pressure regulating valve needsto be placed on the drainage line from the sealto maintain a pressure in the seal housing 15 30 pounds higherthan the tank pressure A filter on the inlet to the sealis recom mended Itisalso recommended that a check valve on the inlet line be installed to prevent back flow of tank contents in case of loss of pressure in the flushing line Pay specialattention to seal housing temperature during operation Neverallow heat buildup in seal housing Increase flow of flushing waterto coolthe seal 9 6 DOUBLE MECHANICAL SEAL W
30. re are long idle periodsbetween operating cycles and d plant department opera tion is shut down Store mixerin a clean dry location with circulating airfree from wide variations in temperature Electric motorsare easily damaged by moisture Store the entire unit off the floor covered with plastic and use desiccantsto reduce moisture build up Do not sealthe plastic coverasthistraps moisture If the motor shows signs of moisture absorp tion before start up dry the motorout by applying 10 voltage on two leads if in doubt measure resistance in windings This will give approximately 50 rated current There are also sprays available to help dry out motors Relubricate motor before sart up when in storage sx months ormore When gear drive models have been in storage formore than a year the condition of the gearlubricant needsto be inspected see Section 7 Lubrication SECTION 2 MOUNTING 2 1 Flange mount Standard 150 flanges are provided Referto the Data Sheet in the front of this manual forthe specific size supplied A gasket needs to be installed between the tank nozzle and the mixer flange to stop leakage of tank contents and keep tank pressunzed Using lock washers ordouble nutting the mounting bolts is recommended to prevent bolts from loosening by equipment vibration 2 2 Mounting structure must be stable and strong enough to hold the full mixer weight torque and overhung moment Please contact Sharpe Mixersfor these
31. ry seats and primary rings 11 18 To replace the shaft in it s original position once the mechanical seal hasbeen replaced to its original position first tighten the two split coupling bolts Remove the retraction bolts from the retraction collar and remove the retraction collar from the mixershaft Replace the collarapproximately an inch from the bearing spool Reinstall the bolts into the tapped holesin the retraction collar The bolts are notto fit into the tapped spoolholes They are to be tightened againstthe face of the bearing spool Tightening the bolts now will push the shaft into the tank Move the mixershaft back approximately 1 8 into its original position the two bearing setscrews Reinstall the service window and gasket The mixerisnow ready forservice See Section 8 and 9 forseal start up and operation 11 19 Tighten the two coupling bolts Tighten 512 Le SECTION 12 MEC HANIC AL SEAL REPLAC EMENT top entry and side entry without shaft retraction feature 12 1 We strongly recommend that you keep one or more spare seals or rebuild kits in stock for quick replacement as many seal parts are not immediately available and could cause extended unwanted shutdowns Often when a seal problem arises the customer will go through two or more seals before the cause of failure isdetermined Because of the wide array of designs sizesand material configura tions available in mechanical seals the suppliers shelves oft
32. salts the chlorides chlorates sulfates sulfides Cool by flushing or by utilizing water jackets 8 6 4 CONGEALING LIQUIDS Generally speaking these liquids congeal either because of a drop in temperature orasa result of drying out afterexpo sure to air Sugarsyrupsfall into both categories A good rule isto keep the fluid moving before congeal ing can take place Control with heatand orby flush or purge Clean liquid flush pressure needsto be 25 psi greaterthan tank pressure a Asphalt isa typical case of a liquid which congealsasit cools and thiscan be controlled by heat Some sugar syrups fall underthis category Be sure to heat thoroughly before start up during operation and after shutdown if followed by a purge b Some products harden to a solid state when exposed to air Glue molasses paint sugarsare examples An effective flush isa dead end lubricator This will keep out the air Note that this type of flush does not enter the product but only mixes with the product leak age It may also be desirable to purge utilizing a solvent of the liquid being mixed Periodically vent dead end lubricated sealsto clean chamber SECTION 9 MEC HANIC AL SEAL LUBRICATION 9 1 SEALLUBRICATION is required at all times during operation of the mixing equipment The only excep tion are dry running seals which are clearly stated in the seal description in the front of this manual 9 2 Lubrication system designs are asvaried
33. tend seal life 9 3 4 NOTE Some smaller side entry mechanical sealshave the seal mounted on the tank side of the mounting flange This ensures abundant lubrication and flow to the seal faces but exposed seal is very vulnerable and requires great care in handling This seal design requires the mixer to be removed from the tank to replace the seal but incorporatesa sec ondary low pressure packing style backup seal to temporarily retain tank contents until mixer re moval isconvenient The purpose of this packing isto control leakage not prevent it Packing must leak to perform properly otherwise they will bum up TFE packing is especially sensitive in this respect DO NOTOVERTIGHTEN Permit generous leakage Gradually take up gland nuts 1 6 tum 1 flat in hex nuts ata time Watch temperature NEVER PERMIT HEATTO DEVELOP BACK OFF GLAND NUTS IF M DOES Asleakage levels off tighten at 15 minute intervals until leakage is controlled without developing heat 9 4 SINGLE EXTERNALLY MOUNTED SEAL This design positions the rotating elements of the seal outboard from the tank contents and islubricated by one of the following means 9 4 1 Seal flushing requires a line of lubricant usually water plumbed to the seal housing and a line from the seal housing to a drain In this design the seal housing will usually incorporate a lip sealto contain the lubricant in the housing but will not hold pressure within the seal housing Therefo
34. tion out of the tank and furtherinto the split coupling The shaft needsto move approximately 1 8 before further retraction becomes difficult Thistightness indicates that the seal collar and gasket has pressed tightly against the tank side of the mounting flange and a proper static seal isattained 11 5 Tighten the two split coupling bolts 651 Be sure to clean the shaft above the mechanical seal so asnot to damage it in removal 11 6 Remove the retraction bolts from the retraction collarand bearing spool Remove the retraction collar 11 7 Follow section 12 paragraphs 12 1 12 2 12 4 12 6 12 7 and 12 8 before continuing 11 8 Clean the inside diameter of the retraction collar Replace the collaron the shaft asclose to the mounting flange aspossible Tighten the collaron the shaft 11 9 Install the retraction bolts into the threaded holes in the retraction collar and tighten Tightening these bolts will hold the shaft in place while the bearing spool is removed from the mounting housing 11 10 Loosen the two split coupling bolts 11 11 Remove the bolts mounting the bearing spool to the mounting flange housing CAUTION Be sure to remove the drive slowly and straight out so asnot to disrupt the static seal at the mounting flange Re move the drive from the housing 11 12 Remove the seal housing and seal from the FMSSM 7 04 shaft CAUTION Take great care in removing the seal Be sure shaft isdebumed and cleaned
35. values if they are not listed on the outline dra wing in the front of the manual Mounting to an unstable support may cause unac ceptable mixing damage to the equipment tank or other hazards 2 3 Side Entry Flange mount Tie rodsare normally provided with side entry mixers The tie rods need to be positioned approximately 45 above horizontal and 45 from the mixer shaft centerline These aid in the support of the mixerand need to be attached securely see paragraph 2 2 for mounting strength requirements If pipe legsare supplied see specific mixeroutline drawing else where in this manual for pipe leg size required SECTION 3 INSTALLING THE MIXER SHAFT amp IMPELLER referto pages 12 or 13 WARNING Always lockout power before installing orremoving mixer shaft or impeller 3 1 The mixer shaft will have one end marked motor end ground to fit the drive bearing and coupling Slide the impeller s onto the opposite end with the concave side of the blades facing AWAY from motor end of shaft A single impelleris best mounted at the end of the shaft or 1 2 prop diameters above tank bottom The upper impeller if supplied is normally mounted a minimum of 2 impeller diameters below the liquid surface Tighten the set screws securely High horsepower units will ha ve divots into which the set screws should be tightened FOR SIDE ENTRY MIXERS skip paragraph 3 2 asthe mixer shaft is installed at the factory 3
36. xer shaft must be hand rotated using input shaft coupling or motor fan with a fixture attached to the shaft to mark a line on the tank bottom NEVER Bow in shaft greatly exaggerated for clarity Shaft axis FMSSM 7 04 APPLY POWER WITHOUT STEADY BEARING INSTALLED The center of this inscribed area will be the location forthe centerofthe steady bearing 5 2 The steady bearing must be securely installed with its vertical centerline coincident with the axis of rotation as established The amount of lateral movement required to bring the shaft into proper alignment with the final teady bearing location will vary depending upon the shaft length and diameter 5 3 The steady bearing isa wearing part and should be checked periodically for wear Path of shaft when rotated by hand J P4 Shaft axis and final location of centerline of steady bearing for proper rotation FIGURE 5 1 SECTION 6 MOTOR CONNECTIONS WARNING High voltage and rotating partscan cause serious or fatal injury Electric machinery can be hazardous Installation operation and mainte nance of electric machinery should be performed by qualified personnel Familiarity with NEMA safety standards National Electric Code and local building codesare required 6 1 Wiring Starting and overload contol devices must be matched to motorrating Follow contro
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