Operatiion & Maintenance Instructions Sharpe Mixers - Side Entry With Seal

8/11/2019 Operatiion & Maintenance Instructions Sharpe Mixers - Side Entry With Seal

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B-1

O P E R A T I O N & M A I N T E N A N C E I N S T R U C T I O N SP E R A T I O N M A I N T E N A N C E I N S T R U C T I O N S

S H A R P E M I X E R SH R P E M I X E R S

S I D E E N T R Y W I T H S E A LI D E E N T R Y W I T H S E L

B1.1 Immediately upon receipt of the equip-ment check the crating and contents for any dam-age that may have occurred in transit. Report anydamage immediately to the carrier and to Sharpe

Mixers. Check against the packing slip to be surethat all parts were received. Report missing items tothe carrier and Sharpe Mixers.

B1.2 Side entry mixers are normally shipped onone skid with the shaft and seal installed and impellerlag bolted to the skid. If space allows, keep shippingcontainers for possible future use.

B1.3 Mechanical Seal receiving and inspec-tion: Thoroughly review the drawings in the servicemanual against the equipment and inspect themechanical seal housing and parts for possibledamage during shipment. Mechanical seals are

easily damaged by improper handling, often unde-tected until the tank contents leak through the seal.NEVER LIFT MIXER BY THE MIXER SHAFT. When liftingthe equipment with a lifting strap, never allow thestrap to come in contact with the mixer shaft, me-chanical seal housing, piping or related compo-nents. Study carefully the mechanical seal drawingto determine whether seal is a single, or doublemechanical seal design. Double mechanical sealsare pressure tested at the factory using air. It isrecommended that double mechanical seals bepressure tested again using air or water pressure prior

to installing the equipment on your tank. When usingair, the seal faces may need to be coated withlubricant to achieve a static seal.

B1.4 Storage: Storage is when a) mixer hasbeen delivered to the job site and is awaiting installa-tion, b) mixer has been installed, but regular opera-tion is delayed, c) there are long idle periods be-tween operating cycles, d) plant/departmentoperation is shut down. Store mixer in a clean, drylocation, with circulating air, free from wide variationsin temperature. Electric motors are easily damagedby moisture. Store the entire unit off the floor, cov-ered with plastic, and use desiccants to reducemoisture buildup. Do not seal the plastic cover as thistraps moisture. If the motor shows signs of moistureabsorption before start-up, dry the motor out byapplying 10% voltage on two leads ( if in doubt,

measure resistance in windings, one to three meg-ohms is normal). This will give approximately 50%rated current. There are also sprays available to helpdry out motors. Relubricate motor before start-upwhen in storage six months or more. Storage ofmixers over six months must have gear reducers filledcompletely with storage oil. Do not install vent plugwhen in storage. Spray oil on exposed lip seals andunpainted carbon steel parts. Rotate motor andgearbox shafts periodically. When returning toservice, drain storage oil, clean with mineral spirits,and replace with correct lubricant (see Section C).

SECTION B

INITIAL INSPECTION, RECEIVING AND STORAGE

TABLE OF CONTENTS

SECTION A MIXER DATA SHEET & DRAWINGS............................................................................................................. A-1SECTION B INITIAL INSPECTION, RECEIVING AND STORAGE .....................................................................................B-1 MOUNTING THE DRIVE ............................................................................................................................... B-2 INSTALLING THE MIXER SHAFT .................................................................................................................... B-2 INSTALLING THE MIXER IMPELLER ............................................................................................................... B-3 STUFFING GLAND PREPARATION & LUBRICATION(o p tiona l eq uipm ent) ............................................. B-4 MECHANICAL SEAL PREPARATION & LUBRICATION(op tiona l eq uipm ent ) ......................................... B-5 MOTOR CONNECTIONS & LUBRICATION ................................................................................................. B-8 START UP & OPERATION ............................................................................................................................. B-9 TROUBLE SHOOTING GUIDE..................................................................................................................... B-12 WARRANTY................................................................................................................................................ B-15

RECOMMENDED SPARE PARTS ................................................................................................................ B-15SECTION C SPEED REDUCER LUBRICATION & MAINTENANCE .................................................................................. C-1 SPEED REDUCER PARTS ............................................................................................................................. C-3SECTION D MISCELLANEOUS DETAILS & INSTRUCTIONS(when required ) .....................................................................


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B-2

MOUNTING THE DRIVE

B2.1 Mounting structure must be stable andstrong enough to handle torque, bending moment,and weight specified on assembly drawing. Thestructure must not flex or vibrate when the mixer is inoperation. If mounting to an unstable support, mixerloads may cause damage to the equipment, tank, orother hazards.

CAUTION: DO NOT LIFT MIXER BY THE SHAFT.DO NOT LIFT THE MIXER USING THE LIFTING LUG OF THEMOTOR ALONE. USE SLINGS TIGHTENED AROUND THEMIXER DRIVE.

B2.2 Tie rods are normally supplied on sideentry mixers. The tie rods need to be positionedapproximately 45above horizontal and 45from themixer centerline. These aid in the support of the mixer

and need to be attached securely. Alternately,when pipe legs are supplied, see specific size calledout on assembly drawing in Section A. See FiguresB2.1 and B2.2 for mounting details.

B2.3 Flange mounts must have gasketsbetween flanges before bolting securely for proper

sealing. When a remote seal is used, seal must beconcentric and perpendicular to mixer shaft. Usinglock washers or double nutting the mounting bolts isrecommended to prevent bolts from loosening byequipment vibration.

B2.4 When foot mounted motors are supplied,readjust the motor after installation for proper align-ment of the flexible coupling (see Paragraph B10.8).

6.0"

NOZZLE LENGTH

7TANK CENTERLINE

MIXERSHAFT

&MOUNTINGN

OZZLECENTER

LINE

TANK DIAMETER

45

D

(D/2) + 6"

TANK BOTTOM

INSTALLING THE MIXER SHAFT

machined section of shaft. Install the mixer shaft frombelow and through seal (if present, see ParagraphB3.1). Install the shaft into the drive (see Figure B3.1).Be sure key is in place. Do not hammer parts inplace. If keys do not fit, grind to size. Before boltinghold washer in place, add NEVER -SEEZ compound(supplied) to the top of shaft. Tighten the holdwasher securely. Reinstall the hollow bore cover

(when supplied).

B3.3 Split coupling drive: Remove split cou-pling from drive shaft. Raise mixer shaft from belowand through seal (see Paragraph B3.1). Bolt holdwasher to top of mixer shaft (if not already done).Install keys on both shafts. Do not hammer parts inplace. If keys do not fit, grind to size. Make sure allparts are clean, and assemble split coupling halvesonto shafts (see Figure B3.2). The split coupling hasone end marked "drive" on each half. These endsmust face the gearbox for proper alignment. Re-

FIGURE B2.1

FIGURE B2.2

WARNING: Always lockout power beforeinstalling or removing mixer shaft.

B3.1 Normally, side entry mixers have the mixershaft and seal installed at the factory. If not, mixersmust have the mixer shaft installed through the sealarea carefully. Some seals will have parts (shipped

separately from the drive) which need to be installedin sequence while installing the mixer shaft. Refer tothe detail drawings in front of the manual. If yourmixer has a split mechanical seal (see data sheet)the seal must be installed after the mixer shaft is inplace. Split seal assembly instructions will be includedin Section D. Note the type of couple to the drive onthe assembly drawings and install shaft per thefollowing means:

B3.2 Hollow bore drive: Remove hold washerand protective wrap on top of mixer shaft. Clean


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B-3

FIGURE B3.2FIGURE B3.1

Mixer shaft

Outputshaft Key

Hold bolt

Hold washer

Mixer drive

place split coupling. Be sure gap is even on bothsides of coupling. Tighten split coupling bolts to the

torque ratings listed in Table B3.1. Tighten from thecenter out, in an opposite/diagonal sequence.

Bolt Torque Ratings (split coupling bolts only)

5/16" bolt @ 10 ft.-lbs. 3/8" bolt @ 25 ft.-lbs.



7/8" bolt @ 200 ft.-lbs.

B3.4 Remove motor fan guard and turn fan byhand to check that mixer shaft turns freely and

alignment is true. Repeat once impellers are in-stalled.

Table B3.1

WARNING: Always lockout power beforeinstalling or removing impeller.

B4.1 Refer to mixer assembly and impellerdetail drawings for proper impeller rotation, position-ing, and placement.

B4.2 1-Piece Impellers: Slide the impeller onthe shaft facing the correct way (according to theassembly drawings). Impellers without keys setscrewdirectly onto shaft. When divots are in the shaft, boltthe setscrew directly into divot. For impellers withkeys, tighten the setscrew securely over the key. Donot hammer parts in place. If keys do not fit, grind tosize.

B4.3 Split Hub Impellers: Clamp split hubimpellers to shaft. If impellers where shipped with

shims, discard prior to assembly, do not use toassemble on mixer shaft. Be sure to maintain 1/8"gap between hubs to insure correct blade alignmentand vibration free operation. Tighten split hubimpeller bolts to the following torque ratings:

Bolt Torque Ratings (split impeller bolts only)


3/4" bolt @ 96 ft.-lbs. 7/8" bolt @ 150 ft.-lbs

B4.4 If a washer is supplied on the end of shaft,tighten in place after installing impeller.

Table B4.1

INSTALLING THE MIXER IMPELLER

Split Coupling Drive

Mixer shaft

Splitcoupling

Outputshaft Key

Hold washer

Hold bolt

Mixer drive

Mixershaft Key

Hollow Bore Drive


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B-4

STUFFING GLAND PREPARATION & LUBRICATION(optional equipment)

FIGURE B7.2

FIGURE B7.3

B7.1 The purpose of packing is to controlleakage, not prevent it. Packings must leak toperform properly, otherwise they will burn up. TFEpackings are especially sensitive in this respect.

B7.1.1 DO NOT OVER TIGHTEN THE PACKING!Permit generous initial leakage on side entry units.Gradually take up gland nuts 1/6 turn (1 flat in hexnuts) at a time. Watch temperature. NEVER PERMITHEAT TO DEVELOP- BACK OFF GLAND NUTS IF IT DOES.As leakage levels off on side entry units, tighten at 15minute intervals until leakage is controlled withoutdeveloping heat. On a 1" dia. side entry shaft,permit 5 to 20 drops per minute, a 2" shaft would beallowed to leak twice as much, etc. TFE packingmust be permitted to leak 30 drops per minute on a1" dia. shaft.

B7.1.2 PROVIDE FOR LUBRICATION, particularlywhen mixing non-lubricating liquids (high pressure

glands only). For greasing, a zirc fitting is standardfrom the factory (see Paragraph B7.3 for lubricationinstructions). For flushing , remove the 1/8" N.P.T. zircfitting and replace with flushing lines (not included).Whenever flushing through a seal, a clean liquidhaving lubricating properties must be used.

B7.2 High pressure packed gland: Seven ringswith lantern ring is standard from the factory. Thisgland is designed for 150 psi of tank pressure. A zircfitting is present on the seal housing and needs to begreased daily. A weight loaded lubricator or otherself lubricating device is available from Sharpe Mixersto aid in seal lubrication.

B7.3 REPACKING THE GLAND: Packing tools:Special flexible corkscrew tools specifically designed

for packing make seal servicing an easy task (seeFigure 7.1). Various size tools are available fromSharpe Mixers.

B7.4 Once power has been disconnectedand shaft retraction has occurred (see Section A),remove the old rings. If a lantern ring is present, thereare (4) slots cut into the top outside edge. This helpsthe packing tools "grab" the lantern ring for removal.Use caution when removing old rings. Do not scoreshaft. Before installing the new rings, be sure that thenew packing is of the proper type and size for yourapplication (see Data Sheet in front of manual).

B7.5 If you purchase your packing rings fromother than Sharpe Mixers, chances are you will haveto cut the rings yourself. To do this, wind the packingaround a mandrel of the same diameter as the mixershaft for the desired number of rings (see FigureB7.2). Cut rings by making a straight cut along the

mandrel as shown. When removing rings frommandrel, slip them off without opening the rings. Thisis especially important for metallic types. Do notopen with a hinge-like action (see Figure B7.3).

B7.6 Check condition of stuffing box and theshaft in the seal area. If either are rough or scored, itneeds to be reworked or replaced. Without repairingthe damaged areas, gland take-up will result indistortion of the rings and over compression of the

FIGURE B7.1


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B-5

packing on the mixer shaft. The packing will not sealproperly and will burn out sooner, further damagingthe seal area. If wearing in the seal area is evidentcontact the factory for recommendations.

B7.7 Coat new rings with a lubricant to assistwith installation and break-in (Do not use on foodgrade packings, liquid oxygen service, nitric acid, orany other non-compatible application). Check

position of all gland parts against the applicable sealdrawing. Replace all worn or damaged parts.

B7.8 Install rings over the shaft by twisting openas shown in Figure B7.3. This is especially important formetallic rings. NEVER open rings with hinge likeaction.

B7.9 Insert rings one at a time with jointsstaggered 90apart. Seat each ring individually,compressing in place with a tamping tool or by usinga split hollow cylinder. Turn mixer shaft occasionallyto assist seating. Unless each ring is properly seated,the gland follower will not be able to tighten thepacking set, as it will leave the front rings (nearestthe follower ring) too tight in the stuffing box. Bear inmind that, except for abrasives, 70% of the wear

normally takes place on the two packing ringsnearest the follower ring. Proper seating and lubrica-tion spreads the wear out more evenly over the entireset of rings. Adjust follower finger tight only to begin.After shaft has been replaced to proper runningposition, see Paragraph B7.1 for seal start-up proce-dures.

MECHANICAL SEAL PREPARATION & LUBRICATION(optional equipment)

B8.1 Mechanical seals are precision ma-

chined, fragile components that are easily damagedby careless handling. Any servicing of mechanicalseal must be handled in a clean white coatmanner. Even a fingerprint on the mating seal facescan cause premature leakage. Most premature sealfailures are due to lack of lubrication or improperinstallation. Seal manufacturers offer mechanicalseal maintenance seminars or seal schools to helpservice personnel understand seal operation. Theminimal cost and time required for this education iseasily justified when you consider the expense downtime and loss of product which occurs when me-chanical seals fail prematurely.

B8.1.1 Do not allow the mixer to be wiredbefore preparing the seal for operation. The electri-cian may bump start the mixer to check for rotationand ruin the seal in the process. Many doublemechanical seals have assembly positioning tabswhich hold the seal wear sleeve on center in positionor compress the seal to running height during ship-ping and assembly. These tabs must be rotated outof the way or removed completely before start-up.

B8.1.2 If the seal has not been installed at thefactory, Install seal over shaft at time of shaft installa-tion in correct position. Use a light vegetable oil toaid in installation over shaft. Compress seal to heightshown in seal detail drawing in front of this manualonce shaft installation is complete. Split seals must befully installed after shaft installation is complete. Seespecific seal details elsewhere in this manual.

B8.1.3 The mechanical seal housing or glandplate will have one or more tapped holes for lubrica-tion, ventilation, and draining, which will be pluggedfrom the factory with temporary plastic plugs. Theseplugs must be replaced with the proper flush/lube/recirculating lines or dead end plugged as describedbelow (Paragraph B8.4).

B8.1.4 Make sure all valves are open to insure

the seal receives a positive flow of liquid at all times.Bleed all gasestrapped in the seal cavity beforestart-up, or the cavity may vapor lock and the sealwill burn up by running dry. Open valves slowly oncethe lubrication system has been pressurized. Open-ing inlet valves too quickly may cause a "waterhammer" effect that could crack or shatter the sealfaces. On high speed (above 350 rpm) and hightemperature applications the mechanical sealhousing must be constantly flushed with a coolinglubricant before applying power to the mixer, or heatwill quickly build and destroy the seal. Where colderambient temperatures will cause thickening of thelubricant, the seal housing and lubricant lines must

be preheated to allow free flowing lubricant to sealbefore start-up. Never allow the seal or lubricationlines to freeze.

B8.2 Tank liquid level must be filled to at leastone prop diameter above the impeller elevationbefore starting mixer. Mixer must never run whenliquid level drops below this point. A low liquid alarmor shut-off switch is recommended if low liquid levelsare likely to occur.

B8.3 SEALING ABRASIVE LIQUIDS: As used hereabrasives is a broad term intended to cover theproblem of sealing against slurries, congealing l iquids,crystallizing salts and the like. They cause the great-est damage to equipment, and present difficulties formechanical seals. In general, the cure involvesflushes, purges, and temperature controls. Seemechanical seal lubrication (Paragraph B8.4) formore information on lubrication and flushing ofmechanical seals.

B8.3.1 SUSPENDED SOLIDS: Solids which aresuspended in liquids and which are an inherent partof their structure would include starch, contaminatedor muddy water, sand, and other slurries. This is besthandled by an external flush of clean liquid through a


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B-6

Air Purge Valve

Plug

throttle. Flushing pressure needs to be 15 - 30 psigreater than tank pressure.

B8.3.2 PRECIPITATING LIQUIDS: Solids whichprecipitate out of a liquid do so by reason of eitheran increase in concentration, or because of alowering (or in some cases a raising) of temperaturebeyond that at which it is proper to operate. Illustra-tions are caustic soda and calcium hydroxide. With

ammonium nitrate, for example, temperature mustbe controlled at an optimum level in relation to itsconcentration. If the temperature rises above theoptimum, it will boil and form crystals, and converselyif temperature drops, it will become saturated andsalt out.

B8.3.3 EVAPORATING LIQUIDS: Solids can formas a result of heat which promotes evaporation.Examples include any of the hot chemical salts - thechlorides, chlorates, sulfates, sulfides. Cool by flushingor by utilizing water jackets.

B8.3.4 CONGEALING LIQUIDS: Generally

speaking, these liquids congeal either because of adrop in temperature, or as a result of drying out afterexposure to air. Sugar syrups fall into both categories.A good rule is to keep the fluid moving beforecongealing can take place. Control with heat and/or by flush or purge. Clean liquid flush pressure needsto be 25 psi greater than tank pressure. (a) Asphalt isa typical case of a liquid which congeals as it cools,and this can be controlled by heat. Some sugarsyrups fall under this category. Be sure to heatthoroughly before start-up, during operation, andafter shutdown if followed by a purge. (b) Someproducts harden to a solid state when exposed to air.Glue, molasses, paint, sugars are examples. An

effective flush is a dead end lubricator. This will keepout the air. Note that this type of flush does not enterthe product, but only mixes with the product leak-age. It may also be desirable to purge utilizing asolvent of the liquid being mixed. Periodically ventdead end lubricated seals to clean chamber.

B8.4 Lubrication of mechanical sealsis re-quired at all times during operation of the mixingequipment. The only exception are dry runningseals which are clearly stated in the seal descriptionin the data sheet and assembly drawings. Seespecific seal data (Section D) in this manual for moreinformation on dry running seals.

B8.5 Lubrication system designs are as variedas customers applications. Listed below are sometypical application designs. Study the seal drawingand description in this manual and circle the lubrica-tion system that best describes your application.Reservoirs, filters, rotameters, flow and pressurecontrol valves and gauges as required, may bepurchased from Sharpe Mixers.

B8.6 SINGLE INTERNALLY MOUNTED SEAL: Thisdesign has the rotating elements of the seal in

contact with the tank contents, and is lubricated bythe following means:

B8.6.1 Lubricant flushing - (see figure B8.1)requires a line of compatible lubricant (usually water)plumbed to the housing at a higher pressure than thetank. This allows a constant flushing of cleansinglubricant through the seal housing and into the tank.It is recommended that a filter, pressure regulator,

and flow control rotameter be installed in that orderon the line to the seal.

TankSide

FIGURE B8.1

Single internal seal with flushing

TankSide

FIGURE B8.2

Single internal seal(lubricated by tank contents)

Check Valve

Filter

PressureRegulator

Plug

Flow ControlRotameter

B8.6.2 Lubricated by tank contents - (seefigure B8.2) this system (for side entry only) requiresthe tank contents to have lubricating properties andto be clean of any solids. Any suspended solids ordissolved solids that may crystallize will build up in theseal housing and cause premature seal leakage.


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B-7

B8.6.3 The plugs in the seal housing need tobe replaced by permanent stainless steel plugs (if notfurnished). After filling tank, bleed all gases trappedin the seal housing or vapor lock may ruin the seal. Ifflushing is not used, periodic bleeding of the sealcavity will cleanse the solids buildup and extend seallife.

B8.7 SINGLE EXTERNALLY MOUNTED SEAL:This

design positions the rotating elements of the sealoutboard from the tank contents and is lubricated byone of the following means:

B8.7.1 Seal flushing - (see figure B8.3) requiresa line of lubricant (usually water) plumbed to the sealhousing and a line from the seal housing to a drain.In this design, the seal housing will usually incorporatea lip seal to contain the lubricant in the housing, butwill not hold pressure within the seal housing. There-fore, a flow restriction and pressure reducing valvemust be incorporated in the supply line to the seal.An in-line filter is also recommended. Never allowpressure to build within the seal housing or you may

blowout the lip seal. The drainage line must riseabove the elevation of the seal housing by a fewinches to guarantee seal will be lubricated withoutsiphoning and must be free flowing to preventpressure buildup.

TankSide

FIGURE B8.3

Single external seal with flushing

TankSide

FIGURE B8.4

Single external seal with lubrication

Double seal with flushing

TankSide

FIGURE B8.5

be installed on the seal to maintain a pressure in theseal housing 15-30 pounds higher than the tank

pressure. A filter on the inlet to the seal is recom-mended. It is also recommended that a checkvalve be installed on the inlet line to prevent backflow of tank contents in case of loss of pressure in theflushing line. Pay special attention to seal housingtemperature during operation. Never allow heatbuildup in seal housing. Increase flow of flushingwater to cool the seal.

B8.9 DOUBLE MECHANICAL SEAL WITH NATURALCONVECTION LUBRICANT RESERVOIR: (see figureB8.6) This design requires a lubricant reservoir (usually2-5 gallon capacity) mounted 6"-18" above, and nomore than 3 ft. away from the mechanical seal.

These systems are often furnished by Sharpe Mixers,mounted on the agitator and fully plumbed to theseal housing. Lubricant circulation occurs when thelubricating fluid, heated by the seal, expands andbecomes lighter and rises out of the seal to the top ofthe lubricant reservoir. Once in the reservoir the fluidcools becoming heavier and returns to the mechani-cal seal housing. This process may be aided bycooling coils in the reservoir. Natural convectionrequires low restriction plumbing as follows: Use largediameter tubing (1/2" recommended) from the uppermostport in the seal housing to the upper liquid input

B8.7.2 Oil Cup - (see figure B8.4) requires a

light oil or other compatible lubricating liquid tocompletely fill the small external cup. This cup mustbe checked periodically. If lubricant has drained,mechanical seal must be checked for possibleleakage.

B8.8 DOUBLE MECHANICAL SEAL WITHTHROUGH FLUSHING: (see figure B8.5) This systemrequires a lubricant line plumbed to the seal (usuallywater) and another line from the seal housing to thedrain. A flow control valve on the inlet, and apressure regulating valve on the drainage line, must

Check Valve

Filter

Flow ControlRotameter

Pressure

RegulatorDrain (higher)

Oil Cup

Plug

Check Valve

Filter

Flow ControlValve

PressureRegulator

Drain


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B-8

MOTOR CONNECTIONS & LUBRICATION

B9.4 Electric motors - Single phase: If yourmixer is supplied with a single phase motor it may bewired by the factory with a ten foot cord and an on/off switch. If no cord or switch is provided refer to thewiring diagram on the motor for correct connections.Check that the switch is in the off position before

plugging the cord into a 110 volt outlet. Chec k forprope r rota tion! Interchange lines if necessary forproper rotation. (See assembly drawing).

B9.5 Electric motors - 3 phase: Motors requir-ing 3 phase power must be wired according to thewiring diagrams on the motor. Rotation of theimpeller must be according to the assembly drawingand data sheet. Interchange lines if necessary forproper rotation.

B9.6 Electric DC Variable Speed: Direct

B9.1 WARNING: High voltage and rotatingparts can cause serious or fatal injury. Electricmachinery can be hazardous. Installation, operation,and maintenance of electric machinery should beperformed by qualified personnel. Familiarity withNEMA safety standards, National Electrical Code andlocal building codes are required.

B9.2 Wiring: Starting and overload controldevices must be matched to motor rating. Followcontrol manufacturer's instructions for proper con-nections and installation.

B9.3 Electrical connections must conform toNational Electrical code and all local regulations.Line voltage and wire capacity must match motorrating stamped on motor nameplate.

TankSide

FIGURE B8.6

Double seal with convection lubrication

like) since thicker materials will not flow, creatingheat buildup and premature seal failure. If tank ispressurized, maintain 15 - 30 psi above tank pressurein the lubricant reservoir. This is accomplished byeither a permanent air line to the top of the reservoirwith a pressure regulating valve, a nitrogen tank orother compatible pressurized medium. A backpressure valve may be incorporated to prevent theback flow of tank contents in case of seal failure

during a loss of pressure in the supply system. A lowpressure shut off switch may also be used to shutdown the mixer in case of a seal system failure.

B8.9.2 Many lubrication reservoirs incorporatecooling coils to further remove heat from thelubricating fluid on high temperature applications.Other lines may also be required to cool the sealhousing or flange. These will be shown in the sealassembly drawing. Cooling water must circulate atall times when heat is present.

B8.9.3 A 10 weight oil (or other thin noncorro-sive lubricating liquid) is recommended rather than

water as a lubricating medium for the seal.

B8.10 DOUBLE MECHANICAL SEAL WITH POSI-TIVE FLOW LUBRICATION SYSTEM: This system utilizes aremote lubricant reservoir with a pump supplyingpositive flow to and from the seal often with a coolingsystem, pressure and flow control valves, low levelalarms and other integrated systems which requirethorough study and preparation prior to start-up. It isrecommended that you contact the appropriatemechanical seal representative in your area forassistance with any questions you may have on moreintricate systems.

in the lubricant reservoir. The return line runs from thebottom of the reservoir to the lower port in the sealhousing. Care must be taken not to attach the returnline to the cooling coil inlet or outlet (if present) whichare also in the bottom of the reservoir. Refer to thereservoir drawing for the orientation of the inlets andoutlets. Keep horizontal runs to a minimum.

B8.9.1 Fill theseal reservoir until liquid level ishigher than upper most plumbing line. Rechecklevel after mixer has run a few minutes and replenishif necessary. Operating liquid must be thin (water

Check Valve

LubricationReservoir

PressureRegulatorNitrogen

Cool

Hot


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B-9

current variable speed electric motors using an SCRcontroller must be wired following the instructionssupplied with the controller. Many adjustments areoften required to the SCR controller and instructionsmust be read carefully before applying power. Seedata sheet and assembly drawings for possible RPMlockout ranges. Operate only at speeds outlined onthose sheets. Damage to equipment or serious injuryto personnel can result, if speed limitations are not

followed.

B9.7 Electric AC Variable Speed: Electricmotors using an AC variable frequency controllermust be wired following the instructions supplied withthe controller. Many adjustments are often requiredto the controller and instructions must be readcarefully before applying power. See data sheetand assembly drawings for possible RPM lockoutranges. Operate only at speeds outlined on thosesheets. Damage to equipment or serious injury topersonnel can result, if speed l imitations are notfollowed.

FIGURE B10.1 FIGURE B10.2

START UP & OPERATION

B10.4 Rotate mixer shaft by hand to checkshaft straightness and assure that the impeller is freeof any obstructions in the tank.

B10.5 Extended operation of the mixer whenliquid level is at or near the impeller is not recom-mended.

B10.6 The impeller rotates in the directionshown in the assembly drawing. Opposite rotationmay cause overload and inefficient mixing.

B10.7 Vortexing may occur if liquid level is tooclose to the upper impeller. This will cause aerationof the product and excessive vibration of the equip-ment. When mixing products of dissimilar viscositiesand/or specific gravities the lighter or less viscousmaterial should be introduced first. Gradually addthe heavier material or powders into the center of

B9.8 WARNING: Ground the mixer motorproperly to avoid serious injury to personnel. Ground-ing needs to be in accordance with the NationalElectrical Code and consistent with local buildingcodes.

B9.9 Other types of motors (e.g.: hydraulic)must be installed per the motor manufacturer

instructions. See data sheet and assembly drawingsfor possible RPM lockout ranges. Operate only atspeeds outlined on those sheets. Damage to equip-ment or serious injury to personnel can result, if speedlimitations are not followed.

B9.10 Motor lubrication: Electric motor bearingsare often sealed and need no relubrication. Whenzirc fittings are present, relubricate with a No. 2consistency lithium soap base and petroleum com-pound. Relubricate every 6 months to 3 yearsdepending on usage. Open and clean drains. Addgrease until new grease is forced out drain. Removeexcess grease and replace input plugs. Run motor

one half hour before replacing drain plugs.

B10.1 WARNING: High voltage and rotatingparts can cause serious or fatal injury. Lockout/Tagout power before servicing.

B10.2 Some models may be shipped "dry"(without lubricant) and must be filled with the properlubricant before start-up. Refer to Section C for the

proper type and amount of lubricant. Units shippedwith oil will have the gearbox vent has been re-placed with a temporary plug for shipment. Ventmust be reinstalled prior to start-up or damage mayoccur. Check that the oil level is to the proper level(see Section C), and that none was lost duringshipment/installation before start-up.

B10.3 Prior to applying power, test line resis-tance to check for possible moisture in the motor.Refer to Paragraph B1.3. Do not apply power if anyresistance exceeds one to three meg-ohms.


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mechanical variable drives) run only at speeds setforth on data sheet and drawings in front of thismanual. DO NOT RUN ABOVE OR BELOW SPEEDS ONDATA SHEET OR ASSEMBLY DRAWINGS. Specific dataon these special drive components are locatedelsewhere in this manual (Section D).

B10.12 Keep motors free from oil, dust, dirt,water, and chemicals. Keep air intakes and outlets

free from foreign material. Electric motors supplied,although designed for outdoor use, may be dam-aged due to weather. A rain hood or other protec-tion may be necessary to prolong motor life. Consultfactory for recommendations.

B10.13 Regular maintenance is the bestassurance of trouble free, long life mixer operation.Inspect and relubricate at regular intervals. Fre-quency and thoroughness depends on operation,nature of service, and environment.

CAUTION: Before start-up, replace OSHAguards provided. Serious injury may occur if not

replaced.

B10.14 In the event of a break down within thewarranty period, Sharpe Mixers must be notifiedwithin 15 days if it is intended that the warranty is tocover the problem. When requesting spare/replace-ment parts anytime, have serial number and modelnumber off mixer nameplate readily available. Donot disassemble components or otherwise modifyequipment without prior authorization from SharpeMixers or warranty will be voided. Sharpe Mixers willnot accept back charges for any repair work thathas not been previously authorized.

the tank while the agitator is running. Never dumplarge amounts of powder or solids into the mixingtank. This may create clotting or sanding in ofimpeller and cause damage to the equipment.

CAUTION: DO NOT START MIXER WITH IMPELLERBURIED IN SOLIDS OR WITH LIQUID SOLUTION SOLIDI-FIED. DAMAGE WILL OCCUR.

B10.8 If impeller is buried in solids prior tostarting mixer, solids must be dispersed. This may beachieved with an air hose, a recirculating pump, or alarge stirring stick if necessary (depending on tanksize).

B10.9 Align flexible motor coupling (on footmounted motors only), to reduce wear of flexibleinsert of coupling. Check parallel alignment byplacing a straight edge across the two couplingflanges and measuring the maximum offset at variouspoints around the coupling (See Figure B10.1). DONOT rotate the coupling. This dimension must be lessthan 0.015". Check angular alignment with a micom-

eter or caliper. Measure the outside of one flange tothe outside of the other at intervals around thecoupling (See Figure B10.2). Find the maximum andminimum dimensions. DO NOT rotate the coupling.The difference between the maximum and minimummust not exceed 0.015". Recheck both parallel andangular alignments again. Shims may be required toadjust properly.

B10.10 Shaft seal must be lubricated/flushedduring operation of mixer.

B10.11 When variable speed drives are used(AC variable frequency, air or hydraulic motors, &


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B10.15 Start-Up Checklist Prior and during start-up please check that the following things have been done:

a. Manual has been read and followed

b. Coupling bolts torqued to specifications

c. Hold washer tight (when applicable)

d. Impeller is immersed in liquid

e. Sufficient protection for motor (if outdoors)

f. Impeller installed correctly (see assembly drawings)

g. Gearbox vented

h. Mounting / Impeller bolts tight

i. All guards in place

j. Proper type and amount of lubricant (see Section C)

k. Wiring correctly installed, grounded and insulated

l. Proper shaft rotation (see drawings & data sheet)

m. Steady bearing installed properly (when applicable)

n. Motor checked for moisture absorptionResistance (less than 3 meg-ohms):

o. Correct voltage/amperage @ start-up:

Motor nameplate F.L.A.:

F.L.A. measured with ampmeter:

Actual line voltage measured:

p. Excessive vibration of mixer support ?

q. Speed limitations set on variable speed controller(when applicable)

r. Proper seal lubrication (when applicable)

s. Proper seal run-in time allowed

t. Mechanical seal position tabs removed (when applicable)

s. Mechanical seal lubrication ports plugged / plumbed with lube

INSPECTOR DATE


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TROUBLE SHOOTING GUIDE

PROBLEM POSSIBLE CAUSE SOLUTION

Shaft will not fit into drive Set screws extend into bore Loosen set screwsor coupling Shaft over size Measure and consult factory

(proper dia. 0.001" - 0.002"

under nominal dia.Damaged shaft Consult factoryOversize key Grind key to fit

Mixer will not Incorrect wiring Check wiring diagramstart and wire correctly

Loose connections Check and tightenconnections

Blown fuse Replace fuseIncorrect voltage Wire for correct voltageImpeller interference Free all debris for rotationWater damage to Service or replace motor

motor (consult factory)Wrong size heaters in Replace heaters

starter

Mixer will not Overload of motor Check amperage against reach correct nameplate data speed Loose drive coupling bolts Check coupling bolt tension

(coupling and/or shaftmaybe damaged ifmixer has been run withslipping coupling)

See Mixer will not start

Motor runs hot / Low or high voltage Wire for correct voltage

Amperage overload Product too viscous Check viscosity and specificgravity of product(consult factory)

Restricted ventilation Clear ventsFrequent starting and Check with factory - a special

stopping motor may be requiredUnbalanced voltage Consult electrician

between phasesIncorrect rotation Change motor leads per

nameplate instructionsProduct too viscous Check viscosity and specific

gravity - consult factoryIncorrect rotation or upside-down Check against assembly drawings -

impeller correct if required

Impeller too close to tank floor raise impellerLack of/improper lubricant Add or change lubricant

(see Section C)Improper output speed Confirm speed - consult factoryBuild up of sediment on tank bottom Clean or irrigate sedimentUndersized heaters Replace with correct heaters


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Noisy Insufficient lubricant Fill proper amount of lubricantForeign material in Change lubricant

lubricant

Incorrect lubricant Change to correct lubricantWorn or faulty bearings or Check bearings/gearsgears replace if necessary

Incorrect coupling alignment adjust/align couplingBent/broken guards Straighten/replace guard

Bearing failure High temperature Provide heat shieldproduct

Excessive overhung load Consult factoryWater damage Replace bearing

(check all other parts)See all items under Noisy

Gear failure Excessive loading Consult factory(check amps)

Lack of (or improper) Fill with recommendedlubrication lubricant or equivalent

(see Section C)Start-stop-start loading Free impeller of any solids at

(product burying start-up (pre stir with airimpeller with solids) hose or paddle)

Foreign material in lubricant Replace lubricant

Oil leakage Excessive lubricant Check manual for properamount lubricant anddrain excess

Damaged/broken gasket Replace gasketLoose bolts around Check and tighten bolts

side platesSeals worn or Replace seals

damagedVent not installed/clogged Replace seals - install/unclog vent

Shaft vibration Impeller not immersed in liquid Fill tankImpeller too close to surface Fill tank or lower impeller

(see Section B4)Bent mixer shaft Consult factoryUnstable mounting platform Reinforce platformLoose or improperly assembled Assemble securely (see Para. B4)

couplingDebris in coupling Clean and reassembleDamaged gearbox bearings Check and replace if necessaryDebris on impeller Clean impellerLoose or bent impeller blades Tighten or straighten

(consult factory)


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Seal leakage Proper amount of leakage See Paragraph B6Worn packing Replace packingScored shaft Replace shaft and packing

check stuffing box alsofor possible scoringInsufficient/incorrect lubrication Lubricate properly

(see Paragraph B7)check for scoring- replace if necessary

Excessive heat in gland Back off gland nuts(replace packing ifnecessary) check forscoring - replace ifnecessary

Worn vapor seal Replace lip sealSplit in packing rings not offset Remove packing, reinstall at

offset (see Paragraph B7)Charred / glazed packing Improper run-in, replace packing

(see Paragraph B8)Worn mechanical seal Replace sealDamaged mating ring Replace mating ringSolids in seal gland Flush properly

(see Paragraph B8)Scored shaft Replace shaft and seal;

lubricate/flush sealInsufficient/incorrect lubrication Lubricate properly

(see Paragraph B8)Excessive heat Lubricate properly or consult

factory, a special sealmay be required

Incorrect seal position See drawings in front of manualfor correct position

Excessive shaft runout See "Shaft vibration" above

Note: Other trouble shooting guides for special optional equipment will be located in Section D (when present).


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WARRANTY

We warrant every SHARPE MIXER to do the job

for which it is recommended, and, if a MIXER fails inthis, we w ill refund the p urcha se p ric e o r provide,

without ad ditiona l cha rge, a mixer whic h will do thejob spec ified . The mate rials of w hic h the MIXER is

constructed, while not guaranteed against chemical

atta c k, are wa rrante d to b e as spe c ified by the

buyer, or it's c om me rcial equivalent. We will eitherrep air or rep lace , at our option a nd a t our expe nse,any part o f a MIXER whic h our examinat ion sha ll

disclose to our satisfaction to be defective in material

or wo rkma nship.

We will pa y a ll transportat ion c harge s relat ive

to o ur rep airing o r rep lac ing a MIXER, althoug h wewill not be respo nsible for remo va l, loa d ing, insta lla -

tion, o r, simila r rela ted expenses.

This wa rran ty extend s for twe lve (12) mo nths

a fte r first insta lla tion o f the MIXER or fo r eightee n (18)

mo nths a fter its shipme nt from our fac tory, whicheverocc urs first.

THE FOREGOING OBLIGATIONS OF THIS WAR-RANTY ARE EXPRESSLY IN LIEU OF ALL OTHER WARRAN-TIES EXPRESSED OR IMPLIED INCLUDING THE WARRAN-TIES OF MERCHANTABILITY AND FITNESS FOR USE ANDOF ALL OTHER OBLIGATIONS OR LIABILITIES ON OUR

PART, AND STATE OUR ENTIRE AND EXCLUSIVE LIABILITYAND BUYER'S EXCLUSIVE REMEDY FOR ANY CLAIM FORDAMAGES IN CONNECTION WITH THE SALE OR FUR-NISHING OF GOODS OR PARTS, THEIR DESIGN, SUIT-ABILITY FOR USE, INSTALLATION OR OPERATION. WENEITHER ASSUME, NOR AUTHORIZE ANY OTHER PERSONTO ASSUME FOR US, ANY OTHER LIABILITY IN CONNEC-

TION WITH THE SALE OF THIS MIXER. WE WILL IN NOEVENT BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIALOR CONSEQUENTIAL DAMAGES OR DELAY WHATSO-EVER, AND OUR LIABILITY UNDER NO CIRCUMSTANCEWILL EXCEED THE CONTRACT PRICE FOR THE GOODS

FOR WHICH LIABILITY IS CLAIMED. THIS WARRANTYSHALL NOT APPLY TO THIS MIXER OR ANY PARTTHEREOF WHICH HAS BEEN SUBJECT TO ACCIDENT,NEGLIGENCE, ALTERATION, ABUSE, OR MISUSE. WEMAKE NO WARRANTY WHATSOEVER IN RESPECT TOACCESSORIES OR PARTS NOT SUPPLIED BY US.

A NOTE ON RECOMMENDED SPARE PARTS

B13.1 Recommended spare parts are different for individual needs. The main factor affecting whichparts should be kept on the shelf of the user is downtime (allowable time period the mixer can be out ofservice). This list shows acceptable downtime and parts to stock on shelf that, under normal circumstances,Sharpe Mixers cannot supply in less time.

Allowable Downtime Recommended parts to stock for repair due to long delivery

3 weeks -Steady bearing bushings, wear sleeves, stuffing gland throttles/bushings,side entry mixer shafts, special alloy seals, special motors.

2 weeks -Above parts, plus: gearbox gear sets, motors, mechanical seals.

1 week -Above parts, plus: gearbox seals, bearings, gaskets, shims, motors, flexible couplings.

3 days -Above parts, and/or: complete gearbox, gland packing, v-belts.

1 day -Complete agitator.

Note: Shafts and impellers, although not normally wearing parts, may be damaged and require repair/replacement. These parts are long delivery items and should be considered if extended down time is unac-ceptable.

For any downtime, all wearing parts are normally recommended spares. These include: bearings, seals,gears, input couplings, and shims/gaskets. V-belts, steady bearing bushings, and wear sleeves are also recom-mended when present.


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MAINTENANCE NOTES:

Description Date By

Documents

Operatiion & Maintenance Instructions Sharpe Mixers - Side Entry With Seal