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STS M-1500H Operator's Manual

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Surface to Surface Inc.
Operators Manual
** M-1500H **
USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED)
Unit Serial No. _______________
Hydraulic Motor
SNM2/19C106 – Serial No.__________________
Gorman-Rupp Pump
GR-84B2 – Serial No. ________________
Control Valve
Brand FC51 Serial No.__________________
Links relating to this Manual
www.stsmixers.com
www.grpumps.com
Dealer
STS-143 Rev. 07/27/12
www.stsmixers.com

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  • Page 1 ® Surface to Surface Inc. Operators Manual ** M-1500H ** USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED) Unit Serial No. _______________ Hydraulic Motor SNM2/19C106 – Serial No.__________________ Gorman-Rupp Pump GR-84B2 – Serial No. ________________ Control Valve Brand FC51 Serial No.__________________ Links relating to this Manual www.stsmixers.com...
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  • Page 3: Table Of Contents

    STS Inc Warranty………………………………………………………….. Safety Statements………………………………………………...………… 7-10 Safety Markings……………………………………………………………. Hydraulic Connections / Schematic…………………………...…………. Main Working Components (Photo)……………………………………… Introduction to the M-1500H ………………..………..….………….……. M-1500H Foot Print (top view)………………………….….……...……… M-1500H General Data Sheet………………………………..…...………. Identifying Your Machine & Components…….…….…….…….………. SECTION II ( Description, Care and Maintenance) Polyethylene Plastic Reservoir Tank…………………….……………...
  • Page 4 Shutdown, cleanup & storage Warm weather…………………………………….…………. Cold/ freezing weather………………………………….…… Prolonged periods of storage………………………………… **Optional self-loading feature……………………………...………… SECTION V (Trouble shooting) Trouble Shooting the M-1500H ……….…….….…….……..……… 45-46 SECTION VI (Periodic Maintenance & Repair Information) Maintenance Schedule…………………….….………………….…... Centrifugal Trash Pump Seal Replacement………………………..… Bolt torque Specifications…………………………………….……...
  • Page 5 TABLE OF CONTENTS PAGE SECTION VII (OEM Repair / Information) GR Centrifugal Pump Owner’s Manual……………………..………… 53-64 Gruvloc® Pipe Couplings ………….…….….….………………..…… 65-67 Sauer Danfoss Hydraulic motor …………..…….….….….….….……. 68-70 SECTION VIII (Parts Manual) M-1500H PARTS MANUAL …………….…..….…….….….….…. 72-77...

  • Page 6: Sts Inc Warranty

    Limited Warranty United States and Canada Surface to Surface Inc. or it’s subsidiary which last sold the product, warrants new products sold by it for use in the United States and Canada to be, at the time of manufacture, free from defects in workmanship and materials. This warranty covers for a period of Twelve (12) Months of operation from the date of delivery for initial use, whichever comes first.

  • Page 7: Safety Statements

    M-1500H SAFETY STATEMENTS Your personal safety and the safe operation of this unit are the concern of Surface to Surface Inc, and by reading and understanding this manual and understanding the safety statements, you will decrease the risk of personal and equipment damage.
  • Page 8 M-1500H SAFETY STATEMENTS The following caution statements have been drawn from the instructions in this manual. They have been assembled here for ready reference. DANGER WARNING NEVER ATTEMPT TO REMOVE IN AN EMERGENCY OR CLEAN THE FILTER SHEAR rota te the flow control va lve w hile the unit is in opera tion.
  • Page 9 M-1500H SAFETY STATEMENTS continued The following caution statements have been drawn from the instructions in this manual. They have been assembled here for ready reference. CAUTION CAUTION WHEN T RANSFERRING FLUID T RAPPED FLUID M AY BE PRESENT to the drill rig, fluid pressure may and will spill out when piping, hoses, reach or exceed 50 p.s.i.
  • Page 10 M-1500H SAFETY STATEMENTS continued The following caution statements have been drawn from the instructions in this manual. They have been assembled here for ready reference. CAUTION CAUTION LIFTING LUGS OR THE LIFTING POINT(S) BEFORE LIFTING OR MOVING THE UNIT, identified and labelle d on the skid all fluid should be rem oved from the tank.

  • Page 11: Safety Markings

    M-1500H Safety Markings Hazard and warning markings have been placed at appropriate points on the unit. International symbols have been used, in order to ensure universal understanding of the nature of the hazard. Please comply with all warnings and markings to ensure safe use of the equipment. These include but are not limited to:...

  • Page 12: Hydraulic Connections / Schematic

    M-1500H These guidelines must be followed or warrant will be voided. Any variation needs to be approved by Surface to Surface®. SET-UP Minimum Flow Rate: 15.0 us gpm. Maximum Flow Rate: 16.5 us gpm. Relief Setting: 2250psi. Inlet Hose Size: 3/4"...

  • Page 14: Introduction To The M-1500H

    (1-800-567-0978) if you have any questions or concerns about your M-1500. Thank you, for choosing the M-1500 series mixer. The M-1500H mixing unit was designed to mix dry or liquid drilling products with clean water, into a slurry. The slurry is continually circulated through the mixing cycle until it reaches the desired consistency.

  • Page 16: M-1500H General Data Sheet

    M-1500H Mixer Hydraulic The M-1500H was designed and manufactured as a dual tank system that allows the HDD contractor two methods of mixing their bentonite mud requirements. This system allows the operator to mix 750 gallons of full yield mud in less then eight (8) minutes, while holding 750 gallons of water reserve in the second tank for the next mix, or mix 1500 gallons of full yield mud in less then sixteen (16) minutes, in one large batch.

  • Page 17: Identifying Your Machine & Components

    M-1500H Identifying Your Machine & Components Location of Tags and PIN Plates...

  • Page 18: Description, Care And Maintenance

    SECTION #II Description, Care and Maintenance...

  • Page 19: Polyethylene Plastic Reservoir Tank

    M-1500H Description, Care and Maintenance Polyethylene Plastic Reservoir Tanks (750 us. gal) Maintenance of this tanks is required, but is simple. The tanks should be cleaned on a regular basis by opening the drain cap on the tank tee, located at the bottom right end of the tank (see Fig.1) and or open the customer installed bottom tank drain (see Fig.2) and rinse the tank with clear water.
  • Page 20 M-1500H Description, Care and Maintenance Polyethylene Plastic Reservoir Tanks (750 us. gal) INSTALLATION OF TANK DRAIN (CUSTOMER INSTALLED)  Find a suitable location on the tank floor for the drain to be installed, taking into consideration the placement of the unit on a trailer. LOOK under the deck for obstructions (cross-members, wiring, and axles, ect.) Allow room for a shut off valve.

  • Page 21: Hydraulic Powered Centrifugal Pump

    M-1500H Description, Care and Maintenance Hydraulic Powered Centrifugal Pump Care and maintenance of the hydraulic motor and pump are covered in this manual and/or the manufacturer operator’s manuals supplied and should be read and understood. We suggest the following daily checks be carried out prior to using the system. Check the fluid level in YOUR hydraulic reservoir is sufficient.
  • Page 22 M-1500H Description, Care and Maintenance Hydraulic Powered Centrifugal Pump Fig.4 CAUTION TRAPPED FLUID MAY BE PRESENT and will spill out when piping, hoses, pump or filter shear are removed. CAUTION NEVER LEAVE LIQUID IN THE PUMP CASING, PIPING, OR HOSES during freezing weather conditions, as damage will result.
  • Page 23 M-1500H Description, Care and Maintenance Hydraulic Powered Centrifugal Pump Grease cup instructions (Fig.5) Fill the grease cup through the grease fitting with No. 2 lithium base grease until grease escapes from the relief hole. Turn the grease cup arm counterclockwise until it is at the top of the stem; this will release the spring to apply grease to the seal.
  • Page 24 M1500H(GR) Description, Care and Maintenance Hydraulic Powered Centrifugal Pump Grease cup instructions (Fig.5a) GREASE CUP NEEDS TO BE CLEANED REGURALY  The grease cup may not perform its function properly (lubricating the seal) if it is not routinely cleaned of old hard grease build-up. If the grease cup is always “topped up” instead of allowed to run to the full stroke of the plunger, the grease may dry out and build up inside of the cup and not allow the plunge to push to the full stroke.

  • Page 25: Filter Shear System

    M-1500H Description, Care and Maintenance Filter / Shear System The filter / shear (Fig.6a) system on the M-1500 is an integral part of the mixing system and to operate efficiently requires daily cleaning of the stainless steel internal filter /shear. The filter / shear system is a two- piece unit (Fig.6b) consisting of an outside housing and an internal filter / shear.
  • Page 26 M-1500H Description, Care and Maintenance Filter / Shear System continued On top of the filter / shear housing (Fig.7) are three outlets that have 2” NPT ball valves connected to them. The outlets are labeled for their functions. An outlet will be labeled and connected to the internal jet gun (explained further on in this manual) mounted inside of the 1 reservoir tank.

  • Page 27: Venturi Mixing Tee

    M-1500H Description, Care and Maintenance Venturi Mixing Tee The Venturi Mixing Tee (Fig 8a.) is the very heart of this system and requires very little maintenance. However M-1500 parts may wear as a result of the application in time and require replacement. This wear will become evident, when the operator notices a reduction in the vacuum that helps pull in the dry product from the hopper.

  • Page 28: Wash Wand

    M-1500H Description, Care and Maintenance Wash Wand The M-1500 is equipped with a pressurized wash wand (Fig.9a) for clearing obstructions and accumulation in the jetting tee. It is recommended that the jetting tee be cleaned with the wash wand after the introduction of material into the hopper after each batch.

  • Page 29: Dry Hopper With Table & Hopper Valve

    M-1500H Description, Care and Maintenance Dry Hopper with Table and Hopper Valve The Dry Hopper and Table (Fig.10) are used during the initial mixing of the dry product and fluid. The hopper and table require very little daily maintenance, however care should be used that this unit does not become overloaded.

  • Page 30: Internal Tank Jet Gun

    M-1500H Description, Care and Maintenance Internal Tank Jet Gun The Internal Jet Gun(s) (Fig.11a) are located inside the polyethylene plastic reservoir tanks, and their main function is to keep the slurry product in the tank moving. This function assures the elimination of dead spots in the tank and a consistent mixture of fluid.

  • Page 31: Set-Up And Installation Of Unit In Detail

    SECTION #III Set-up and Installation of Unit in Detail...

  • Page 32: Permanent Mounting Of Unit

    M-1500H Set-up and Installation of M-1500 in detail Permanent mounting of the unit The M-1500 is built on 2 sub frames that can be bolted down to a permanent surface like a concrete pad, pull type trailer, flat deck of a truck or inside of a truck body. Securing the units with adequate size and grade of fasteners is the sole responsibility of the customer and not of Surface to Surface Inc.

  • Page 33: Operating The M-1500H Unit

    SECTION #IV Operating the M-1500H Unit...

  • Page 34: Site Set-Up And Pre-Check

    M-1500H Operating the M-1500 Unit Site Setup & Pre-Check SITE SETUP  CHECK for overhead hazards if unloading the unit to the ground.  UNLOAD the unit by using the sub frame fork pockets (marked) with appropriate equipment.  and position the unit on solid level surface to avoid settling or upset.

  • Page 35: Starting The Hydraulic Driven Pump

    M-1500H Operating the M-1500 Unit Starting the Hydraulic Motor & Pump Starting the hydraulic driven pump  Make sure the hydraulic variable speed control lever (Fig.13) is in the stop position (all the way over to the left stop pin).

  • Page 36: Typical Mixing Operation

    M-1500H Operating the M-1500 Unit Typical Mixing Operations Guide lines for Mixing  Always operate the motor and pump at high speed.  Open the hopper valve at the bottom of hopper where it joins the venturi mixing tee.  Introduce the dry or liquid raw material into the hopper.
  • Page 37 M-1500H Operating the M-1500 Unit Typical Mixing Operations Scenario 1  Open the 4” suction valve of the front tank, and #1 jet gun valve. All other valves are to be closed.  With both tanks full of fresh water operate the motor and pump at high speed.
  • Page 38 M-1500(GR) Operating the M-1500 Unit Typical Mixing Operations Scenario 3  Open the 4” suction valves of the front and rear tank, and #1 and #2 jet gun valves. All other valves are to be closed.  With both tanks full of fresh water operate the motor and pump at high speed. ...

  • Page 39: Typical Transfer/Off Loading Operation

    M-1500H Operating the M-1500 Unit Typical Transfer/Off loading Operation Transferring Operation  On the top of the filter / shear housing of the M-1500 you will see a 2 in. ball valve (2”NPT.) marked “Drill Fluid”.  A transfer hose with a minimum size of 2 in. can be attached to the ball valve to carry the finished product to a holding tank or directly to the drill rig.

  • Page 40: Warm Weather

    M-1500H Operating the M-1500 Unit Typical Warm Weather Shutdown & Storage Daily Shut Down  Make sure the mixing tee is rinsed clean with the wash wand and the hopper valve is closed.  Do not rotate hydraulic control valve suddenly while running at high speed.

  • Page 41: Cold/ Freezing Weather

    M-1500H Operating the M-1500 Unit Typical Cold Weather Shutdown & Storage Additional Winter and Freezing Weather Shut Down  Pump or drain remaining mixed fluid out of the tank and dispose of it according to local environmental approved practices.  Make sure “Tank Gun(s)” and “Drill Fluid” valves are open.

  • Page 42: Prolonged Periods Of Storage

    M-1500H Operating the M-1500 Unit Prolonged Periods of Storage Prolonged Periods of Storage After a thorough cleaning of the internal and external components of the M-1500 the following steps should be applied to extend the life of your unit.  Prolonged periods of storage require extra care of the pump to protect from rusting internally. Separate the pump (as you would to replace the seal) to dry and spray with a protective oil film.

  • Page 43: Optional Self-Loading Feature

    M-1500H Operating the M-1500 Unit Optional Self-Loading Feature Self Loading (customer to install) If the self-loading feature of The M-1500 is required, you will find a 2 in. NPT (suction) port located on the venturi-mixing tee below the hopper valve (Fig.14a). All units are shipped with a plug installed in the port.

  • Page 44: Trouble Shooting The M-1500H

    SECTION #V Troubleshooting the M-1500H Unit...
  • Page 45 M-1500H Troubleshooting the M-1500 Unit The M-1500 mixing unit is of a simple design with limited moving parts or consumable pieces. The basic system works with a pump that draws fluid from a reservoir tank. The fluid then exits the pump and by building pressure, and velocity, forces the fluid through the filter / shear and into the mixing Tee.
  • Page 46 M-1500H Troubleshooting the M-1500 Unit  Tank does not stir / roll the fluid inside. No fluid to the tank jet gun - Make sure “Tank Gun” valve is open. Tank jet gun holes plugged. - Flush fresh water through system or clean Tank jet gun...

  • Page 47: Periodic Maintenance & Repair Information

    SECTION #VI Periodic Maintenance & Repair Information...

  • Page 48: Maintenance Schedule

    Basic M-1500 Hydraulic Periodic Maintenance Schedule *** Consult Your Hydraulic Power Source OEM manual(s) for a more detailed maintenance schedule of your equipment. .*** STSI is not to be held liable for any discrepancies or errors in the schedule. Maintenance Items Every Every Every...

  • Page 49: Centrifugal Trash Pump Seal Replacement

    M-1500H Grease Seal Installation Instructions Centrifugal Pump Application When replacing the sea, never mix old and new parts. Wear patterns on the old seal faces cannot be realigned during reassembly, and use of old parts can result in premature failure of the new seal.

  • Page 50: Bolt Torque Specifications

    M-1500H Bolt Torque Specifications Grade 5 Grade 8 Lubricated * Dry ** Lubricated * Dry ** SAE SIZE ft-lbs ft-lbs ft-lbs ft-lbs 13.5 12.5 5/16 7/16 9/16 1050 1300 * "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

  • Page 51: Notes

    M-1500H NOTES: __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________...
  • Page 52 SECTION #VII OEM Repair Information...
  • Page 53 Surface to Surface or your STS distributor. Surface to Surface Inc 1-800-567-0978 Hazards or unsafe practices, which COULD result in minor personal injury or product or property damage.
  • Page 54 SAFETY This information applies to 80 Series basic pumps. The power source, which is used to drive the pump, may differ from unit to unit. Refer to the manual accompanying the power source Make certain that the unit and all piping or before attempting to begin operation.
  • Page 55 SAFETY continued Never run this pump backwards. Be certain Overheated pumps can cause severe that rotation is correct before fully burns and injuries. If overheating of the engaging the pump. pump occurs: 1. Stop the pump immediately. 2. Ventilate the area. 3.
  • Page 56 OPERATION Add liquid to the pump casing when: Review all SAFETY information in this manual. 1. The pump is being put into service for the Follow the instructions on all tags, labels and first time. decals attached to the pump. 2.
  • Page 57 TROUBLESHOOTING Review all SAFETY information in Section A. Before attempting to open or service the pump: 1. Familiarize yourself with this manual. 2. Lock out or disconnect the power source to ensure that the pump will remain inoperative. 3. Allow the pump to completely cool if overheated. 4.
  • Page 58 PREVENTIVE MAINTENANCE Pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine preventive maintenance schedule will help assure trouble-free performance and long life from your 80 series pump.
  • Page 59 GR-84B2 ASSEMBLY PARTS LIST ( P/N #060-GR84B2-KIT ) REF # DESCRIPTION STS PART NUMBER QTY REQ. Hex Nut 060-D105991 Pipe Flange 060-175610010 Flange Gasket 060-1676G18000 Check Valve Seat 060-733610010 HD Machine Screw 060-X040317090 Flap Valve Assembly 060-7340 Hex Head Capscrew...
  • Page 60 PUMP AND SEAL DISASSEMBLY 4. Check the temperature before AND REASSEMBLY opening any covers, plates, or plugs. 5. Close any suction and discharge Review all SAFETY information in Section A. valves. Follow the instructions on all tags, label and 6. Vent the pump slowly and cautiously. decals attached to the pump.
  • Page 61 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Seal Reassembly and Installation (Figures 1 and 3) Impeller Removal Before removing the impeller, screw the cross arm Clean the seal cavity and shaft with a cloth soaked on the automatic lubricating grease cup (1) clock- in fresh cleaning solvent.
  • Page 62 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Pump Casing and Wear Plate Installation Seal Reassembly and Installation continued If the wear plate assembly (11) was removed, (Figures 1 and 3) install the new wear plate in the pump casing and secure it with the hardware (4 & 19). Sub assemble the inboard stationary seat, packing Install a new set of casing gaskets (7) and slide the ring and stationary washer.
  • Page 63 LUBRICATION Fill the grease cup (11) through the grease fitting with No. 2 lithium base grease until grease escapes from the relief hole. Turn the grease cup arm counterclockwise until it is at the top of the stem; this will release the spring to apply grease to the seal (see Figure 4).
  • Page 64 Grease Seal Installation Instructions Centrifugal Pump Application When replacing the sea, never mix old and new parts. Wear patterns on the old seal faces cannot be realigned during reassembly, and use of old parts can result in premature failure of the new seal. Before installing the seal, inspect the bore of the seal liner for excessive wear or grooves that might cause leakage or damage to the seal packing rings.
  • Page 68 Group 2 Gear Motors Technical Information System Requirements Hydraulic fluids Ratings and data for gear motors are based on operating with premium hydraulic fluids containing oxidation, rust, and foam inhibitors. These fluids must possess good thermal and hydrolytic stability to prevent wear, erosion, and corrosion of internal components. They include: ...
  • Page 69 Group 2 Gear Motors Technical Information System Requirements Filtration Filters Use a filter that conforms to Class 22/18/13 of ISO 4406 (or better). It may be on the motor outlet (discharge filtration) or inlet (pressure filtration). Selecting a filter When selecting a filter, please consider: ...
  • Page 70 Group 2 Gear Motors Technical Information System Requirements Reservoir The reservoir provides clean fluid, dissipates heat, removes entrained air, and allows fluid volume changes associated with fluid expansion and during all system operating modes. A correctly sized reservoir accommodates maximum volume changes during all system operating modes. It promotes de-aeration of the fluid as it passes through, and accommodates a fluid dwell-time between 60 and 180 seconds, allowing entrained air to escape.
  • Page 71 SECTION #VIII (Parts Manual)
  • Page 72 BU-750(GR) ASSEMBLY PARTS LIST ( P/N #BU-750(GR) ) STS PART NUMBER QTY REQ. REF # DESCRIPTION Skid Frame SR-75001 4" NPT 90° Street Elbow 018-310-01780-1 4" NPT x Hose Barb 018-1661268266 4" Band Clamp 025-MIK-112-121 4" Flex Hose SR-75078-G 4" Groove x Hose Barb 020-004-00109-9 4"...
  • Page 73 B = Black O = Orange W = White Y = Yellow Pump Outlet " Tank Gun " Decal 070-STS-027-B " Drill Fluid " Decal 070-STS-027-D " Clean Fluid Daily " Decal 070-STS-027-A " Drain " Decal 070-STS-027-C " No Step " Decal 070-15080-B "...
  • Page 74 PU-H4(GR) ASSEMBLY PARTS LIST P/N #PU-H4(GR) STS PART NUMBER QTY REQ. REF # DESCRIPTION Motor / Pump Mounting Base 060-GR84B2-10 1/2" x 2" Bolt 076-13211 1/2" L/W 076-33626 1/2" F/W 076-33012 1/2" Nut 076-36310 Motor Shim S/S 034-QA SHIM PACK Gorman-Rupp 4"...
  • Page 75 GR-84B2 ASSEMBLY PARTS LIST ( P/N #060-GR84B2-KIT ) STS PART NUMBER QTY REQ. REF # DESCRIPTION Hex Nut 060-D105991 Pipe Flange 060-175610010 Flange Gasket 060-1676G18000 Check Valve Seat 060-733610010 CAUTION Keep c up full at all times. HD Machine Screw 060-X040317090 Use #2 lithium base grease.
  • Page 76 4" Groove x Hose Barb 020-004-00109-9 4" Band Clamp 025-M8-113 4" Flex Hose SR-15030-A Pipe Support SR-15009 Pipe Support Shims SR-15009-A as required "KEEP LID CLOSED" Decal 070-STS-030-B 2" NPT Coupler 018-320-01320-4 3/8" x 1" Bolt 076-13105 3/8" L/W 076-33622...
  • Page 77 018-310-01720-7 2" Ball Valve 022-423-00014-0 2" Rubber Hose SR-15030-E Tank Bottom Drain 086-BF-220BD " M-1500 " Decal 070-STS-028-B " Tank Gun " Decal 070-STS-027-B " #1 " Decal 070-STS-027-E " #2 " Decal 070-STS-027-F " Do Not Enter " Decal...

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