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1
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
We also point out that we assume that the motor will be wired
by a knowledgeable licensed electrician who knows how to
correctly wire a semi-standard 3 phase motor for 230, 380, 460,
575, etc., volts. We have also only lightly touched on such
things as in-tank coupling, stuffing boxes, etc., as these are fairly
common in most chemical plants.
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
CONTENTS
Section 1 Preface
Section 2 Safety
Section 3 Storage
Section 4 Installation
Section 5 Lubrication
Section 6 Maintenance
Section 7 Preventative Maintenance Scheme
Section 8 Recommended Spares
Section 9 Trouble Shooting Chart
Section 10 Diagnosing Causes of Helical Gear Tooth Damage
Section 11 Mixer Drawings
Section 12 Tightening Torques
Section 13 Steady Bearings (optional)
Section 14 Lock Washers on in-tank fasteners
Section 15 In-tank Couplings
Section 16 Stuffing boxes
Section 17 Motors
Addendum A Split seals (only included if supplied on project)
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Section 1 Preface
4
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
5
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Two-stage and three-stage CF mixers
(the second digit after CF gives the number of stages – example CF52 has two
stages and CF53 has three stages)
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
13. Flange
14. Oil seal
15. Output shaft
16. Retainer ring
17. Bearing
18. Adjustment washer, bearing
19. Retainer ring
20. Low speed pinion
21. Bearing
22. Second-stage gear
23. Second-stage pinion
24. Bearing
25. Bearing
26. First-stage gear
28. Expansion trunk
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Section 2 Safety
Very important note: This manual
refers to the general class of CF
mixers. Individual units can vary.
Only highly qualified personnel
should do all operations. If the
individuals do not understand the
drive or have any hesitation, then
they should not be allowed to work
on the unit. In addition, it should
be remembered that the mixer is
substantial in weight and must
always be firmly supported so as not
to fall over, fall upon anybody or
anything, etc. All safety
precautions are strictly the
responsibility of the user.
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
9
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
10
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Section 3 Storage
The mixers are not intended for
outdoor storage. They must be
stored in a clean, dry environment at
ambient temperatures between 30 to
100 degrees F.
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
12
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Section 4 – Installation
In order to assure the effective
operation of the mixer, installation,
lubrication and maintenance must be
based on Lotus Mixers instruction
and specifications. Good
judgment, proper design of the
support structure with generous
safety factors, etc. , are also
required.
13
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
14
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
16
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
17
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Section 5 – Lubrication
Type CF53 CF63 CF73 CF83 CF93 CF103 CF133 CF143 CF163
Weight(kg) 65 143 146 165 385 393 710 1185 1892
Oil Qty(L) 1. 1 2. 6 4 9 12. 1 23 35 63 123
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Ambient temperature
19
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
20
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Section 6 – Maintenance
Maintenance is simple.
Type CF52/54, CF62/63 mixers
contain stable lifetime lubricant and
unless there is a loss of oil, no
change is required.
TYPES CF72/73 through CF163
have an oil plug (for shipment) that
should be replied by the expansion
tank.
The oil level should be checked on a
regular basis. Loss of oil should
be check out and corrected but
under no circumstances, should the
mixer be used with a low oil level.
If there is an abnormal condition
such as noise, thrashing, vibration
or temperature rise, etc. , during
operation, the mixer immediate and
21
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
22
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
23
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
24
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
25
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
26
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Section 9 – Troubleshooting
Trouble Reason Correction
1. Change bearing
1. Bearing worn
2. Adjust gap or change bearing
2. The gap of cone roller bearing is too
large or bearing abrasion
1. Abnormal
noise during
3. Gear(s) badly abraded
running 3. Change gear
4. Loosening of connecting bolts
4. Check and tighten bolts
5. The viscosity of lubrication oil is small.
5. Choose oil according to the table
1. Bearing wear
1. Change new bearing
2. The gap of circular cone bearing is too
2. Adjust gap
small
3. Check and adjust proper alignment
3. Bearing abrasion from shaft
nonalignment.
4. Discharge or add oil
2. Abnormal 4. Oil - too much or too little
5. Oil pump not running, or running in reverse
temperature rise of
direction. Air leak from intake end, oil pipe
gear box or bearing 5. Bad lubricating condition
clog, low oil level.
6. Oil deterioration due to lack of use.
6 and 6A. Discharge oil and clean gear box, add
new oil
6A. Water in oil
7. Reduce load
7. Running over load
8. Choose lower viscosity oil
8. The viscosity of lubricating oil too high
4. Vibration during 1. Relative displacement of joint between 1. Check and adjust proper alignment
running two shafts is too large
2. Check if motor, gear box, coupling, stand
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
2. Joint flexure or loosening become flexible and tighten them
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Helical gears normally fail due to overloading situations and consist of the
gear tooth (teeth) breaking off the gear hub.
Other causes can be gear error due to worn housings and bearings
(normally a bearing noise will indicate a bad bearing).
Lotus Mixers has found an interesting paper on fatigue failure (copies are
available on the Internet from the authors:
BS-ISO helical gear fatigue life estimation and debris analysis validation
Muhammad Ali Khan1, a, Dennis Cooper2 and Andrew Starr1
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Section 11 – A complete set of assembly drawings for the mixers have been sent
to the engineering company and/or the end user. Additional electronic copies
can be secured for free from Lotus Mixers at info@lotusmixers.com. Copies are
not available to third parties without written permission from the original buyer or
identified end user.
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Section 12 – Torques
It is impossible to list all the bolt torque values in a general manual as different
materials, sizes and grade bolts are supplied by Lotus Mixers and there is also
the possibility that different materials or grade bolts can be substituted in the
field. Bolt torques are also dependent upon a number of factors including rust,
corrosion, dirt, thread condition, etc.
However, as a general statement, bolts should be tight and the connection rigid.
There are a good number of charts available in the Internet showing maximum
torque values for particular bolts.
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LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
Section 13 – Steady Bearings
Given that some tanks have grown to rather large dimensions with heights in the
range of 50 feet or more, bottom or side mounted steady bearings are becoming
more common. These are normally simple devices that anchor the shaft from
horizontal deflections. While very intuitive, the following should be observed.
As the tank is fabricated by somebody else, we do not weld the steady bearing
supports but rather supply it with legs that should be field fit. The most common
procedure is to install the mixer including the shaft making sure that it is level.
The steady bearing housing is then fit on the shaft so that it is centered. After
doing this, there are several ways of finishing but the easiest is to install the
32
LOTUS MIXERS INC.
3449 Technology Drive, #201
North Venice, FL 34275 USA
Phone: (941) 966-1885
E-Mail: info@lotusmixers.com
Web: www.lotusmixers.com
sleeve and bushing and then bolt them to the housing (see drawing).
490)#!, 34%!$9 "%!2).'