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STS M4-E Operator's Manual

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Surface to Surface Inc.
®
Operators Manual
** M4-E **
USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED)
Unit Serial No. _______________
Teco-Westinghouse Motor
Optim HE PLUS – Serial No. ______________
Gorman-Rupp Pump
GR-84B2 – Serial No. ________________
Links relating to this Manual
www.stsmixers.com
www.twmi.com
www.grpumps.com
Dealer
STS-123 Rev. 02/08/23
www.stsmixers.com

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  • Page 1 Surface to Surface Inc. ® Operators Manual ** M4-E ** USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED) Unit Serial No. _______________ Teco-Westinghouse Motor Optim HE PLUS – Serial No. ______________ Gorman-Rupp Pump GR-84B2 – Serial No. ________________ Links relating to this Manual www.stsmixers.com...
  • Page 2 RESPONSIBILITY FOR DAMAGES OR PERSONAL INJURIES CAUSED BY IMPROPER INSTALLATION. If a problem or concern is found while installation is being done, a call to the appropriate party is recommended. Teco-Westinghouse West 1-800-661-4023 East 1-800-268-4770 Surface to Surface Inc. 1-800-567-0978 STS-024 Rev. 01/04...
  • Page 3 Remove the black insert. Reinstall the guard, and then switch the motor on/off and as the shaft slows down, you will be able to see the rotation direction. If the need be, change the wiring to provide the proper rotation. STS-024 Rev. 09/16...

  • Page 4: Table Of Contents

    STS Inc Warranty………………………………………………………….. Safety Statements………………………………………………...………… 8-11 Safety Markings……………………………………………………………. Main Working Components (Photo)……………………………………… M4 Hose Connections ……………….……………………………………. Introduction to the M4-E ……………….………….………….…………. M4-E Foot Print (top view)………………………………………………… M4-E General Data Sheet…………………………………………………. Identifying Your Machine & Components………………………………. SECTION II ( Description, Care and Maintenance) Electric powered centrifugal pump.…….…………….………….….
  • Page 5 TABLE OF CONTENTS PAGE SECTION IV (Operating the M4 Unit.) Site set-up and pre-check…………………………………………….. Starting the motor and pump………………………..……………… Typical mixing operation……………………….……………………. Typical transfer / off-loading operation……………………………… Shutdown, cleanup & storage Warm weather…………………………………….…………. Cold/ freezing weather………………………………….…… Prolonged periods of storage………………………………… **Optional self-loading feature……………………………...…………...
  • Page 6 TABLE OF CONTENTS PAGE SECTION VII (OEM Repair Information) GR Centrifugal Pump Owner’s Manual……………………..………… 51-62 Teco-Westinghouse Owner’s Manual excerpts ………………………. 63-69 Gruvloc® Pipe Couplings……………………….………………..…… 70-72 Quick-Flex® Drive Coupling……………………….………………..…… 73-76 SECTION VIII (Parts Manual) M4-E PARTS MANUAL…………………….……………….……. 78-80...

  • Page 7: 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 8: Safety Statements

    M4-E 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 9 M4-E 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 shut off all pow er (sw itch) w hile the unit is in operation.
  • Page 10 M4-E 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 TRANSFERRING FLUID TRAPPED FLUID MAY BE PRESENT to the drill rig, fluid pressure may and w ill spill out w hen piping, hoses, reach or exceed 50 p.s.i.
  • Page 11 M4-E 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 The manufacturer s hould be consulted LIFTING LUGS OR THE LIFTING POINT(S) w hen considering alternative uses identified and labelled on the skid for this piece of equipment.

  • Page 12: Safety Markings

    M4-E 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 15: Introduction To The M4-E

    M4-E Operators Manual Congratulations on your acquisition of the world renowned M4 Mixing System. You have acquired the fastest and most efficient mixing system manufactured for mixing Bentonite drilling slurry (mud). As a manufacturer of HDD support equipment, we are well aware of the extreme conditions that HDD equipment is exposed to on a daily basis.

  • Page 16: M4-E Foot Print (Top View)

    64.0" 49.0" 46.0" M4-E(GR) ( Electric ) DRY WEIGHT 1275 lbs. Surface to Surface Inc. ® * Due to our continuing product improvement, specifications are subject to change without notice. * DWR. NUM. DATE. 03 / 03 / 11 M4-E (GR)

  • Page 17: M4-E General Data Sheet

    Teco/Westinghouse electric motor, driving a 4” centrifugal pump, it makes effective use of the proprietary 4 point mixing system. The M4-E can be used as a new installation or retrofitted into an existing system of tank(s). Since the unit is connected by hose and not hard pipe, the placement of the mixer verses the tank(s) is less restricted and a configuration to suit the needs of the contractor are easier to achieve.

  • Page 18: Identifying Your Machine & Components

    M4-E Identifying Your Machine & Components Location of Tags and PIN Plates...

  • Page 19: Description, Care And Maintenance

    SECTION #II Description, Care and Maintenance...

  • Page 20: Electric Powered Centrifugal Pump

    M4-E Description, Care and Maintenance Electric Powered Centrifugal Pump Care and maintenance of the 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.
  • Page 21 M4-E Description, Care and Maintenance Electric 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 22 M4-E Description, Care and Maintenance Electric 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 23 M4-E Description, Care and Maintenance Electric 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.

  • Page 24: Filter Shear System

    M4-E Description, Care and Maintenance Filter / Shear System The filter / shear (Fig.6a) system on the M4 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 25 M4-E Description, Care and Maintenance Filter / Shear System continued On the left side of the unit (near the back side) is an upright “discharge manifold” (see Fig.7). The two outlets are connected to the filter shear and controlled by independent ball valves. The connections are 2”...

  • Page 26: Venturi Mixing Tee

    M4-E Description, Care and Maintenance Venturi Mixing Tee The Venturi Mixing Tee (Fig8a.) is the very heart of this system and requires very little maintenance. However M4 unit 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 27: Wash Wand

    M4-E Description, Care and Maintenance Wash Wand The M4 unit 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 28: Dry Hopper With Table & Hopper Valve

    M4-E 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 29: Internal Tank Jets

    The internal tank jets are connected together in series, usually by a manifold design, (suggested by STS) were all jets receive the same amount of fluid and pressure. This manifold design is supplied with fluid from one of the outlets on the discharge manifold (Fig.11b).
  • Page 30 Connect the manifold to the outlet on the filter/shear of the STS Mixing Unit. Each unit is shipped with 2-4 jet nozzles that have been properly sized for the unit.

  • 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

    M4-E Set-up and Installation of M4 in detail Permanent mounting of the unit The M4 unit is built on a sub frame 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 unit 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 M4 Unit

    SECTION #IV Operating the M4 Unit...

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

    M-4-E(GR) Operating the M4 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 lifting bale (marked) with appropriate equipment. • and position the unit on solid level surface to avoid settling or upset. •...

  • Page 35: Starting The Motor And Pump

    Starting the M4-E Mixer • Since the M4-E is customer installed and the electrical hook up is done by a qualified electrician hired by the customer, the switch (on – off) may differ from one unit to another, therefore the instructions as to its operation will be supplied by the switch manufacture.

  • Page 36: Typical Mixing Operation

    M4-E Operating the M4 Unit Typical Mixing Operation Mixing Operation • With suction valve open and pump full of liquid, switch motor ON. • If not already open, open internal tank jet valve. • Open the hopper valve at the bottom of hopper where it joins the venturi mixing tee.

  • Page 37: Typical Transfer/Offloading Operation

    M4-E Operating the M4-E Unit Typical Transfer/Offloading Operation Transferring Operation • On the discharge manifold of the M4 you will see a 2 outlet with a ball valve (2”NPT.) that is not used. • A transfer hose with a minimum size of 2 in. can be attached to this outlet ball valve to carry the finished product to a holding tank or directly to the drill rig.

  • Page 38: Warm Weather

    M4-E Operating the M4 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. • Switch the motor OFF. • Close the valve on the suction line between the tank and the pump.

  • Page 39: Cold/ Freezing Weather

    M4-E Operating the M4 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 the valves on the discharge manifold are open.

  • Page 40: Prolonged Periods Of Storage

    M4-E Operating the M4 Unit Prolonged Periods of Storage Prolonged Periods of Storage After a thorough cleaning of the internal and external components of the M4, 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 41: Optional Self-Loading Feature

    M4-E Operating the M4 Unit Optional Self-Loading Feature Self Loading (customer to install) If the self-loading feature of The M4 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 42: Trouble Shooting The M4

    SECTION #V Troubleshooting the M4 Unit...
  • Page 43 M4-E Troubleshooting the M4 Unit The M4 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 44 M4-E Troubleshooting the M4 Unit • Tank does not stir / roll the fluid inside. No fluid to the tank jets - Make sure discharge manifold valve is open. Tank jet holes plugged. - Flush fresh water through system or clean Tank jets...

  • Page 45: Periodic Maintenance & Repair Information

    SECTION #VI Periodic Maintenance & Repair Information...

  • Page 46: Maintenance Schedule

    Basic M4-E Electric Periodic Maintenance Schedule *** *** The following items have been listed as basic items to check. The OEM motor manual should be followed. STSI is not to be held liable for any discrepancies or errors in the schedule.

  • Page 47: Centrifugal Trash Pump Seal Replacement

    M4-E 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 48: Bolt Torque Specifications

    M4-E Bolt Torque Specifications Grade 5 Grade 8 SAE SIZE Lubricated * Dry ** Lubricated * Dry ** 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 49: Notes

    M4-E NOTES: __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________...
  • Page 50 SECTION #VII OEM Repair Information...
  • Page 51 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 52 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 53 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 54 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 55 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 56 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 57 GR-84B2 ASSEMBLY PARTS LIST ( P/N #060-GR84B2-KIT ) STS PART NUMBER QTY REQ. REF # DESCRIPTION Hex Nut 060-GRD105991 Pipe Flange 060-GR175610010 Flange Gasket 060-GR1676G18000 Check Valve Seat 060-GR733610010 CAU TION Keep cup full at all times. HD Machine Screw 060-GRX040317090 Use #2 lithium base grease.
  • Page 58 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. 6. Vent the pump slowly and cautiously. Follow the instructions on all tags, label and decals attached to the pump.
  • Page 59 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 (22) clock- in fresh cleaning solvent.
  • Page 60 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Pump Casing and Wear Plate Installation Seal Reassembly and Installation continued If the wear plate assembly (13) was removed, (Figures 1 and 3) install the new wear plate in the pump casing and secure it with the hardware (12). Sub assemble the inboard stationary seat, packing Install a new set of casing gaskets (17) and slide ring and stationary washer.
  • Page 61 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 62 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 63 INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR THREE PHASE INDUCTION MOTORS Frames 143T - 449T 18060-109 Ave. Edmonton, AB. T5S 2K2 Phone: 800-661-4023 Fax: 888-873-8964...
  • Page 64 RECEIVING 1. Check nameplate data. 2. Check whether any damage has occurred during transportation. 3. After removal of shaft clamp, turn shaft by hand to check that it turns freely. 4. If motor is to be reshipped (alone or installed to another piece of equipment) the shaft must again be clamped to prevent axial movement.
  • Page 65 POWER SUPPLY & CONNECTIONS 1. Wiring of motor and control, overload protection and grounding should be in accordance with National Electrical Code and all local safety requirements. 2. Nameplate voltage and frequency should agree with power supply. Motor will operate satisfactorily on line voltage within -10% of nameplate voltage;...
  • Page 66 A. 3 Lead, Single Voltage B. 6 Lead, Dual Voltage & Voltage Ration 1 to 3 B-2 Wye Start & Delta Run (Low Voltage only) B-1 Across the Line Start & Run C. 9 Leads; Dual Voltage & Voltage Ratio 1 to 2, Wye Connected C-2 Part Winding Start C-1 Across the Line Start &...
  • Page 67 D. 9 Leads; Dual Voltage & Voltage Ration 1 to 2, Delta Connected D-2 Part Winding Start (Low Voltage only) D-1 Across the Line Start & Run E. 12 Leads, Dual Voltage E-1 Across the Line Start & Run E-2-1 Wye Start & Delta Run (Low Voltage only) E-2-2 Wye Start &...
  • Page 68 E-3 Part Winding Start (Low Voltage only) *Important: For Part Winding Start, M2 contactor should be closed within two (2) seconds after M1 contactor is closed Only 4 pole and above (e.g., 6P, 8P ) motors are satisfactory for Part Winding Start at low voltage.
  • Page 69 MAINTENANCE INSPECTION Inspect motor at regular intervals. Keep motor clean and ventilation openings clear. LUBRICATION 1. Frame 143T-256T: Double shielded and pre-lubricated ball-bearing motors without grease fittings and don t need relubrication, except on MAX-E1 ¤ and MAX-E2 ¤ products which have regreasable features.
  • Page 73 Installation Guide Timken Quick-Flex Coupling: Standard Coupling ®...
  • Page 74 STANDARD COUPLING INSTALLATION Please complete the following steps to install Timken Quick-Flex INSTALLATION couplings. 1. Check the bore size of the coupling halves and the shafts. Ensure that they are the correct bore size to fit the application. You should have the following pieces before you start the job: 2.
  • Page 75 8. Install the cover: REVOLUTIONS PER MINUTE (RPM) a. High-speed cover: Slide the cover over the hub and insert AND BALANCE until fully rested against the shoulder of the hub. QF5 The Timken Quick-Flex coupling is machined on all surfaces through QF175 use standard snap rings to hold the cover in place.
  • Page 76 TABLE 3. QUICK-FLEX STANDARD COUPLING MISALIGNMENT TOLERANCES Coupling Series Radial Misalignment Tolerance Axial Misalignment Tolerance Angular Misalignment Tolerance 0.51 1.98 2° 0.020 0.078 0.99 2.95 QF15 2° 0.039 0.116 0.99 2.95 QF25 2° 0.039 0.116 0.97 2.95 QF50 2° 0.038 0.116 1.47 3.96...
  • Page 77 SECTION #VIII (Parts Manual)
  • Page 78 BU-M4 (V2) ASSEMBLY PARTS LIST ( P/N #BU-M4 (V2) ) STS PART NUMBER QTY REQ. REF # DESCRIPTION 4" NPT 90° Street Elbow 018-310-01780-1 Pump Discharge Pipe M4-011 4" Groove-Loc Coupler 020-390-00034-7 4" Grooved 90° Elbow 020-390-01430-6 4" Hinge-Loc Coupler...
  • Page 79 PU-E4(GR) ASSEMBLY PARTS LIST ( P/N #PU-E4(GR) ) STS PART NUMBER QTY REQ. REF # DESCRIPTION 20 HP. 3520 rmp. 360/460 V 034-20HP MOTOR Motor / Pump Coulper Hub 036-QF15_1 5/8 P/N #M-750E-010-A Motor / Pump Coulper Insert 036-QF15_INSERT Coupler Cover & Snap Ring...
  • Page 80 GR-84B2 ASSEMBLY PARTS LIST ( P/N #060-GR84B2-KIT ) STS PART NUMBER QTY REQ. REF # DESCRIPTION Hex Nut 060-GRD105991 Pipe Flange 060-GR175610010 Flange Gasket 060-GR1676G18000 Check Valve Seat 060-GR733610010 CAU TION Keep cup full at all times. HD Machine Screw 060-GRX040317090 Use #2 lithium base grease.

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