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STS M2 Series Operator's Manual

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Surface to Surface Inc.
Operators Manual
** M2-E **
USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED)
Unit Serial No. _______________
Teco-Westinghouse Motor
Optim HE PLUS – Serial No. ______________
Gorman-Rupp® Pump
STS-GR82E2 – Serial No. ________________
Links relating to this Manual
www.stsmixers.com
www.grpumps.com
www.twmi.com
Dealer
STS-103 Rev. 11/07/23
www.stsmixers.com

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  • Page 1 ** M2-E ** USE IN CONJUNCTION WITH OEM MANUALS (ENCLOSED) Unit Serial No. _______________ Teco-Westinghouse Motor Optim HE PLUS – Serial No. ______________ Gorman-Rupp® Pump STS-GR82E2 – Serial No. ________________ Links relating to this Manual www.stsmixers.com www.grpumps.com www.twmi.com Dealer STS-103 Rev. 11/07/23...
  • 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 SHAFT AND CAUSE SUFFICIENT DAMAGE TO THE PUMP AND IMPELLER AND OR PERSONAL HARM. To disable the reverse function (if equipped) refer to the manufacture’s installation manual of the variable frequency Drive (VFD) or contact the VDF manufacturer. STS-024 Rev. July/2021...
  • Page 4 FIG. 1...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS PAGE STS Inc. Warranty…………………….….……………………………….. Safety Statements………………………………………………...………… 9-12 Safety Markings……………………………………………………………. Main Working Components (Photo)……………………………………… M2-E Hose Connections ……………….………………….……………. Introduction to the M2 ……………….………..………..…………. M2-E Foot Print (top view)……………………………….…………… M2-E General Data Sheet…………………………………………………. Identifying Your Machine & Components………………………………. SECTION II ( Description, Care and Maintenance) Electrical powered centrifugal pump.…….…………….………….….
  • Page 6 TABLE OF CONTENTS PAGE SECTION IV (Operating the M2-E Unit. Site set-up and pre-check…………………………………………….. Starting the motor driven pump…………….….…..…….……… Typical mixing operation……………………….……………………. 37-38 Typical transfer / off-loading operation……………………………… Shutdown, cleanup & storage Warm weather…………………………………….…………. Cold/ freezing weather………………………………….…… Prolonged periods of storage………………………………… SECTION V (Trouble shooting) Trouble Shooting the M2-E ………….…….….….…..……..……...
  • Page 7 TABLE OF CONTENTS PAGE SECTION VII (OEM Repair / Information) GR Centrifugal Pump Owner’s Manual……………………..………… 52-63 Teco-Westinghouse Owner’s Manual excerpts …….…...….….….…. 64-70 Gruvloc® Pipe Couplings ………….…….….….………………..…… 71-73 Quick-Flex® Drive Coupling ………….……….….……………..…… 74-77 SECTION VIII (Parts Manual) M2-E PARTS MANUAL…………………….…………….……. 79-81...

  • Page 8: Sts Inc. Warranty

    Limited Warranty United States and Canada Surface to Surface Inc. or its 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 9: Safety Statements

    M2-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. Safety statements are listed here and throughout this manual to draw your attention to potential hazards that may be encountered while operating this piece of equipment.
  • Page 10 M2-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 11 M2-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 will spill out w hen piping, hoses, reach or exceed 50 p.s.i.
  • Page 12 M2-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 T he manufacturer should be consulted LIFTING LUGS OR T HE LIFT ING POINT(S) when considering alternative uses identified and labelled on the skid for this piece of equipment.

  • Page 13: Safety Markings

    M2-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: a) Lifting points b) Flammable Liquids c) High temperature areas...

  • Page 15: M2-E Hose Connections

    Surface to Surface Inc. M2 Series (Hose Hook-ups) FLUID OUTLETS [to Drill Rig & Tank Guns] ** 1 1/2" NPT ** PUMP INTAKE [in from Tank] ** 2" NPT ** This line should have a valve installed at the tank to facilitate shut down or reapirs.

  • Page 16: Introduction To The M2

    Surface To Surface Inc. strives to overcome these conditions, with better design and manufacturing practices. Please feel free to call our toll free number (1-800-567-0978) if you have any questions or concerns about your M2 series mixer. Thank you, for choosing the M2 series mixer.

  • Page 17: M2-E Foot Print (Top View)

    31 1/2" 27" 46 1/2" M2-E (Electric) Dry Weight: 460 Lbs (209 Kg) Surface to Surface Inc. ® DWR. NUM. DATE. 02 / 27 / 18 * Due to our continuing product improvement, specifications are subject to change without notice. * M2-E Footprint REV.

  • Page 18: M2-E General Data Sheet

    M2-E Mixer Electric The M2-E universal mixer is designed around the time proven M series mixers of STS. Powered by a 10HP Teco/Westinghouse electric motor, driving a 2” centrifugal pump, making effective use of the proprietary 4 point mixing system. The M2-E may be used as a new installation or retrofitted into an existing system of tank(s). Since the unit is connected by hoses 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 is easier to achieve.

  • Page 19: Identifying Your Machine & Components

    M2-E Identifying Your Machine & Components Location of Tags and PIN Plates...

  • Page 20: Description, Care And Maintenance

    SECTION #II Description, Care and Maintenance...

  • Page 21: Electrical Powered Centrifugal Pump

    M2-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 22 M2-E922 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 23 M2-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 24 M2-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. If the grease cup is always “topped up”...

  • Page 25: Filter Shear System

    M2-E922 Description, Care and Maintenance Filter / Shear System The filter / shear (Fig.6a) system on the M2 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 M2-E922 Description, Care and Maintenance Filter / Shear System continued On the bottom of the filter / shear housing (Fig.7) are two outlets that have 1 1/2” NPT ball valves connected to them. One of the outlets is to be connected to the internal tank jets inside of the reservoir tank (explained further on in this manual) and the other outlet is to be used as a discharge for the fluid after it is mixed.

  • Page 27: Venturi Mixing Tee

    M2-E 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 M2 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

    M2-E Description, Care and Maintenance Wash Wand The M2 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 29: Dry Hopper With Table & Hopper Valve

    M2-E Description, Care and Maintenance Dry Hopper with Table and Hopper Valve The Dry Hopper (Fig.10) is used during the initial mixing of the dry product and fluid. The hopper requires very little daily maintenance. Keeping the inside surface of the hopper clean will help the dry product flow smoothly into the hopper valve and into the mixing tee.

  • Page 30: 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 31 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 32: Set-Up And Installation Of Unit In Detail

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

  • Page 33: Permanent Mounting Of Unit

    M2-E Set-up and Installation of M2 in detail Permanent mounting of the unit The M2 is built on a sub frame with isolators (pucks) attached to the bottom. The unit can be fastened down to a permanent surface like a concrete pad, pull type trailer, flat deck of a truck or inside of a truck body.
  • Page 34 SECTION #IV Operating the M2 Unit...

  • Page 35: Site Set-Up And Pre-Check

    M2-E Operating the M2 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 36: Starting The Motor Driven Pump

    M2-E Operating the M2 Unit Starting the Motor & Pump The Motor Operators Manual should be consulted for a more detailed start up and shut down procedures. Starting the M2-E Mixer • Since the M2-E is customer installed and the electrical hook up is done by a qualified electrician hired by the customer, the switch (on –...

  • Page 37: Typical Mixing Operation

    M2-E Operating the M2 Unit Typical Mixing Operation Mixing Operation: Dry Products • With the tank full of water. • With suction valve open and pump full of liquid, switch motor ON. • If not already open, open internal tank jet valve. •...
  • Page 38 M2-E Operating the M2 Unit Typical Mixing Operation Mixing Operation: Dry Polymers • With the tank full of water. • With suction valve open and pump full of liquid, switch motor ON • If not already open, open internal tank jet valve. •...

  • Page 39: Typical Transfer/Offloading Operation

    M2-E Operating the M2 Unit Typical Transfer/Offloading Operation Transferring Operation • On the bottom of the filter / shear housing of the M2 you will see a second 1-1/2 in. ball valve (1-1/2”NPT.) marked “Outlet”(the first “outlet” is connected to the internal tank jets) •...

  • Page 40: Warm Weather

    M2-E Operating the M2 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 any valve(s) installed on suction line between pump and tank. •...

  • Page 41: Cold/ Freezing Weather

    M2-E Operating the M2 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 both “Outlet” valves are open. •...

  • Page 42: Prolonged Periods Of Storage

    M2-E Operating the M2 Unit Prolonged Periods of Storage Prolonged Periods of Storage After a thorough cleaning of the internal and external components of the M2, 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 SECTION #V Troubleshooting the M2 Unit...

  • Page 44: Trouble Shooting The M2-E

    M2-E Troubleshooting the M2 Unit The M2 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 45 M2-E Troubleshooting the M2 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 Hose is disconnected from tank jets - Reconnect hose No fluid flow/ low fluid flow - See above solutions •...

  • Page 46: Periodic Maintenance & Repair Information

    SECTION #VI Periodic Maintenance & Repair Information...

  • Page 47: Maintenance Schedule

    Basic M2-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. Motor &...

  • Page 48: Centrifugal Trash Pump Seal Replacement

    M2-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. PACKING RINGS Before installing the seal, inspect the bore of the seal liner for SEAL PLATE...

  • Page 49: Bolt Torque Specifications

    M2-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. ** "Dry"...

  • Page 50: Notes

    M2-E NOTES: __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________...
  • Page 51 SECTION #VII OEM Repair Information...
  • Page 52 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 53 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 54 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 55 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 56 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 57 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 58 GR-82E2 ASSEMBLY PARTS LIST ( P/N #060-GR82E2-KIT ) STS PART NUMBER REF # DESCRIPTION QTY REQ. Grease Cup 060-S36 3/8" Nut 060-GRD0615991 3/8" L/W 076-33622 Seal Plate Assembly 060-GR427A10010 Brass Seal Liner 060-GR8314080 Casing Gasket Set 060-GR229G18000 Grease Seal assembly...
  • Page 59 GR-82E2 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.
  • Page 60 GR-82E2 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Seal Reassembly and Installation Impeller Removal (Figures 1 and 3) 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 61 GR-82E2 PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Pump Casing and Wear Plate Installation Seal Reassembly and Installation continued If the wear plate assembly (9) was removed, (Figures 1 and 3) install the new wear plate in the pump casing and Sub assemble the inboard stationary seat, packing secure it with the hardware (2 &...
  • Page 62 PACKING RINGS SEAL PLATE BRASS SEAL LINER SPACER SLEEVE IMPELLER LARGE CHAMFER STATIONARY ELEMENTS ENGINE ROTATING CRANKSHAFT ELEMENTS IMPELLER SHIM WASHERS STATIONARY WASHER STATIONARY SPRING WASHER Figure 3. Grease Seal Assembly LUBRICATION Fill the grease cup (1) through the grease fitting with No. 2 lithium base grease until grease escapes from the relief hole.
  • Page 63 Grease Seal Installation Instructions Centrifugal Pump Application When replacing the seal, 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 PACKING RINGS SEAL PLATE...
  • Page 64 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 65 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 66 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 67 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 68 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 69 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 70 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 74 Installation Guide Timken Quick-Flex Coupling: Standard Coupling ®...
  • Page 75 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 76 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 77 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 78 SECTION #VIII (M2-E Parts Manual)
  • Page 79 BU-M2E ASSEMBLY PARTS LIST ( P/N #BU-M2E ) REF # DESCRIPTION STS PART NUMBER QTY REQ. Crash Frame Electric M2-711 2" NPT Street 90° Elbow 018-310-01720-7 Pump Discharge Pipe M2-603 2" Hinge-Loc Coupler 020-390-20048-3 2" Coupler EPDM Gasket 020-390-078640 Filter Shear Cartrige M2-604 1 1/2"...
  • Page 80 PU-M2-E ASSEMBLY PARTS LIST ( P/N #PU-M2-E) STS PART NUMBER QTY REQ. REF # DESCRIPTION 10 HP. 3600 rmp. 230/460 V 034-10HP MOTOR GREASE Grease Cup 3/8" x 1 3/4" Bolt 076-13110 Instruction 3/8" F/W 076-33008 3/8" L/W 076-33622 3/8" Nut...
  • Page 81 GR-82E2 ASSEMBLY PARTS LIST ( P/N #060-GR82E2-KIT ) STS PART NUMBER QTY REQ. REF # DESCRIPTION Grease Cup 060-S36 3/8" Nut 060-GRD0615991 3/8" L/W 076-33622 Seal Plate Assembly 060-GR427A10010 Brass Seal Liner 060-GR8314080 Casing Gasket Set 060-GR229G18000 Grease Seal assembly...

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