Manual Agitador Tanques

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

January 25, 2013
LOTUS TOP ENTRY MIXERS

Contract __________________
OPERATING, MAINTENANCE &

INSTALLATION MANUAL
NOTE: WE ENCOURAGE YOUR INPUT, COMMENTS &
SUGGESTIONS.
SEE IMPORTANT NOTE ON PAGE 2
THIS manual is the property of LOTUS MIXERS INC. ONLY THE
ENGINEERING COMPANY AND ORIGINAL END USER OR BUYER MAY COPY IT.
TRANSMISSION OF ANY SORT TO A THIRD PARTY WITHOUT THE PERMISSION
OF LOTUS MIXERS INC., IS FORBIDDEN.
CERTIFIED ISO9001
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LOTUS MIXERS INC.
Phone: (941) 966-1885

Before beginning, it should be noted that this is a general

manual. ALL of our mixers are custom made and can have
differences from the so called standard “CF” drive. However,
this should not be a problem for an experienced mechanic as
much is rather intuitive. In any case, if something is not clear,
please contact us immediately.
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.
When working on our mixers, always refer to the assembly

drawing. Typically there will be a parts list with numbers, etc.
For example, the impeller could be a JCX1250. This tells us
that it is a pitched blade turbine with a diameter of 1250 mm
(49.2”). Likewise, the pedestal maybe a JXD80 that defines the
design as well as giving a shaft diameter through the pedestal of
80 mm (3.15”).
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LOTUS MIXERS INC.
Phone: (941) 966-1885

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.
Phone: (941) 966-1885

Section 1 Preface
The CF drive is intended for speed

reduction in top entry mixers.
Depending upon the overall
reduction ratio between the motor
and the output shaft, it can have
either two or three stages using
helical gears.
The CF series is designed to handle

heavy loads, smooth transmission of
power, have low noise, and high
efficiency. The design is intended
to have a logical structure and be
rather intuitive. It is considered a
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LOTUS MIXERS INC.
Phone: (941) 966-1885

“work horse” for vertical mixer

applications.
This manual refers to a general

class of mixers and is non-specific.
Individual mixers may or may not
differ from the description in this
manual.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

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)
6. First-stage pinion shaft

7. Bearing
8. Low speed gear
9. Housing
10. distance sleeve,
11. Retainer ring
12. Bearing
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LOTUS MIXERS INC.
Phone: (941) 966-1885

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.
Phone: (941) 966-1885

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.
Phone: (941) 966-1885

Overall, use common sense and if

something does not “feel right”,
withdraw and consider the situation.
In addition, one should remember
that the gearbox or motor can be hot
and cause injury if touched before
cooling. The safety guards over
the pedestal must be installed and in
place in order to see that no injury is
possible when the mixer is
operating.
The electrical system must have

positive interlocks (it is
recommended that actual locks be
placed on the local control box)
installed so that the mixer can not
be run either automatically or by
throwing a switch when the mixer is
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LOTUS MIXERS INC.
Phone: (941) 966-1885

being touched, maintained or

someone is in the tank.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

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.
The mixers and their components

must not be dragged across the
floor, dropped from a truck or
container, etc. This cannot be
over emphasized when the wetted
parts (shafts, impellers, etc. ) are
rubber (Teflon, fiberglass, etc.), as
they will be damaged (this is not
covered by the warrantee).
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LOTUS MIXERS INC.
Phone: (941) 966-1885

Shafts in the horizontal storage

direction must be supported to avoid
sag or bending. They should
NEVER be stood on, have weight
applied to a span, stored in
cantilever, etc.
The mixers are not a step and must

never be used as such.
GEAR INPUT/OUTPUT SHAFTS
MUST BE TURNED by hand EVERY
45 to 60 days.
Overall, use common sense and if

something does not “feel right”,
withdraw and consider the situation.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

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.
Damage due to improper storage,

installation, abuse, overload,
accidents, Acts of God, abnormal
use, bad lubrication, corrosion, etc. ,
are not covered by the warrantee.
Any damage in transit, missing items
that is not immediately reported and
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LOTUS MIXERS INC.
Phone: (941) 966-1885

noted on the receiving documents

plus backed up by adequate
video/photos, etc. , are also not
covered by the warrantee.
Review all the drawings, data sheet,
etc. , and familiarize the people with
the individual mixer, its features,
rotation, etc.
The mixer is designed to operate
from – 40 degree to 104 degrees F
(40 C).
Make sure the more has the correct

voltage and frequency (Hz) rating for
the local situation.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

Check the levelness of the mounting

beams, flange, etc. Remove any
film, dirt or rust on the face.
If equipped with a protection plug, a

breather plug before running must
replace it.
Check all exterior items on the

reducer and make sure there are no
loosened parts, fasteners, etc. , and
that nothing is damaged.
Uniformly tighten all nuts and bolts.
Make sure there is proper lubricant

inside the mixer and grease in the
appropriate fittings.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

Uniformly tighten the fasteners

firmly.
In-tank fasteners include anti-

vibration locking washers. Make
sure these are installed and folded
back. If these are lost, damaged
or misplaced, they must be replaced.
After everything is bolted together,
rotate the mixer in both directions by
hand. The mixer should turn
smoothly.
With water in the vessel (the mixer

should not be run in air), “bump” the
mixer to make sure it is rotating in
the correct direction (see the
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LOTUS MIXERS INC.
Phone: (941) 966-1885

assembly drawing). If not, re-wire

the connections to the motor.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

Section 5 – Lubrication
In general, we have had good

success with Shell Omala and it
should always be used if available.
There are equivalents shown in the
table but they are secondary
choices. Always check the ISO
grade as the ambient temperature
effects the grade used.
Table 1. Main parameters for CF series two-stage reducer
Type CF52 CF62 CF72 CF82 CF92 CF102 CF132

Weight
65 143 146 165 385 393 710
（kg）
Oil
QTY 1. 2 2. 7 4. 5 8 12. 1 23 35
（L）
Table 2. Main parameters for CF series three-stage reducer
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
List of lubricating oil
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LOTUS MIXERS INC.
Phone: (941) 966-1885

Ambient temperature
-10 to + 15℃ -10 to +40℃
ISO VG150； ISO VG320；
List of lubricating oil supplier
ISO VG Shell BP Mobil ARAL Lotus

Energal
OMALA Mobilgear Degol L-CKC
150 G-R-
OiL 150 629 BG 150 150
XP150
Energal
OMALA Mobilgear Degol L-CKC
320 G-R-
OiL 320 632 BG 320 320
XP320
High quality lithium grease should

be used and added to the bearing
cup(s) as required. The grade
should be selected based upon the
bearing RPM and ambient
temperature.
List of lithium grease with in the bearing
Supplier Lotus Shell Mobil BP

Mobilux Energrease
Grease Lithium grease 2#, Alvanin
LS
brand 3# EP2 EP2；EP3
EP2
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LOTUS MIXERS INC.
Phone: (941) 966-1885

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LOTUS MIXERS INC.
Phone: (941) 966-1885

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
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LOTUS MIXERS INC.
Phone: (941) 966-1885

determine the cause. The mixer

should only be restarted once the
cause is corrected.
If the grease becomes black or the
smell changes rapidly, discharge the
grease and renew.
Periodically check for loose

fasteners, leaks, dirty faces, etc. ,
and correct as necessary.
On all mixers except CF52/53 and
CF62/63 (lifetime oil), the first oil
change is at 800 hours of operation.
Afterwards, changes can be made at
8,000 hours but in no case longer
than 4 years.
If the mixer has lubrication fittings,
regrease these once a year (make
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LOTUS MIXERS INC.
Phone: (941) 966-1885

sure reservoirs are full on a regular

basis).
If the mixer has not been used for a
long time or been exposed to severe
rains, drain and replace the oil.
If the rubber lining is suspect, it can
be spark tested at 5,000 volts
(maximum) using direct current
(alternating current should never be
used) being careful not to overheat
the lining by lingering too long.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

Section 7 – Preventive maintenance

plan.
Please see section 6.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

Section 8 – Recommended spares

The user must consider the critical
nature of each mixer in their plant
operation. recommended spares
can vary from a minimum supply of
extra gaskets, seals and bearings
through having complete spare
mixers ready for immediate
installation.
The end user must consider that

express shipments are not
immediate and can take several
days. It should also be remember
that parts inventories at Lotus Mixes
vary continuously with usage and
that much of the equipment is
custom built for the order.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

Impeller blades should always

consist of a matched set of blades.
Individual blades should not be
replaced as it can cause
balance/vibration problems and not
individual blades.
The end user should contact Lotus

Mixers once they determine the level
of backup needed.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

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
1. Oil level is too high 1. Discharge oil to appoint level
2. Connection face seal failed 2. Clean connection face and resealed

3. Oil leakage from
3. Loosening of connection 3. Tighten bolts, take connection face apart and
output shaft or
reseal
connection face
4. Oil seal abrasion or aged
4. Change oil seal
5. Bearing abrasion from shaft
nonalignment. 5. Check and adjust proper alignment
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.
Phone: (941) 966-1885

2. Joint flexure or loosening become flexible and tighten them
3. Bearing or other parts wearing 3. Change bearing and others part
4. Over loading 4. Reduce load
5. Vibration from gearbox 5. Run reducer by itself, check vibration source
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LOTUS MIXERS INC.
Phone: (941) 966-1885

Section 10 - Diagnosing Causes of Helical Gear Tooth Damage
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.
Phone: (941) 966-1885

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.
Phone: (941) 966-1885

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.
Phone: (941) 966-1885

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.
Phone: (941) 966-1885

sleeve and bushing and then bolt them to the housing (see drawing).
490)#!,34%!$9"%!2).' #(%#+-)8%2
!33%-",9$2!7).'&/2$)&&%2%.#%3
33
LOTUS MIXERS INC.
Phone: (941) 966-1885

Section 14 – Lock washers on in-tank fasteners
In general, Lotus Mixers uses a special lock washer, which is intended to

minimize the chance of loosening. It is obviously installed under the nut.
After torqueing the bolt, it should be bent so as to “lock” over the edge of a blade
and also two edges of the nut. Do not run any mixer without a lock nut on every
fastener.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

Section 15 – In-tank couplings
Most of our in-tank couplings are rabbeted male-female connections. They are
not gasketed. Make sure the connection is flush and not cocked before
torqueing bolts.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

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LOTUS MIXERS INC.
Phone: (941) 966-1885

Section 16 – Stuffing boxes
If equipped with a stuffing box, procedures are very similar to those on pumps
and other equipment in a typical chemical plant. It is important not to over
tighten the gland nuts as it will merely score the shaft and wear the packing
prematurely.
Typical plant practice either on a new mixer or one that has been repacked is to
turn the mixer first by hand to make sure it is not binding. Next the mixer should
be run with the gland nuts fairly loose until the packing has taken a seat.
The gland nuts can then be tightened sufficiently so that leakage is at an
acceptable level. As above never over tighten.
On high pressure stuffing boxes, there is a gland ring, which is typically between
the 3rd and 4th ring of packing. This should be greased prior to assembly and on
a regular basis as needed. Do not OVER GREASE.
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LOTUS MIXERS INC.
Phone: (941) 966-1885

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LOTUS MIXERS INC.
Phone: (941) 966-1885

Section 17 – MOTORS
We suggest checking the website of the motor supplier as they will have the
latest manuals pertaining to the motor.
We have not included diagrams as we use motors that have industry standard
standard wiring. Any competent licensed electrician should have the capability
of wiring a three phase motor for the available voltage (200, 208, 230, 380, 460,
575, etc.).
If the motor is dual or triple voltage rated, make sure it is wired for the correct
value. This is extremely critical as incorrect wiring will cause near instantaneous
motor failure.
In addition to being matching industry standards, most motors have a wiring
diagram on the inside cover of the conduit box.
The CF drive uses either IEC or NEMA frame face mounted motors.
Before finishing, make sure the motor is wired for the proper direction of rotation.
39
LOTUS MIXERS INC.
Phone: (941) 966-1885

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LOTUS MIXERS INC.

3449 Technology Drive, #201

January 25, 2013

LOTUS TOP ENTRY MIXERS

OPERATING, MAINTENANCE &

THIS manual is the property of LOTUS MIXERS INC. ONLY THE

TRANSMISSION OF ANY SORT TO A THIRD PARTY WITHOUT THE PERMISSION

OF LOTUS MIXERS INC., IS FORBIDDEN.

Before beginning, it should be noted that this is a general

When working on our mixers, always refer to the assembly

The CF drive is intended for speed

The CF series is designed to handle

“work horse” for vertical mixer

This manual refers to a general

6. First-stage pinion shaft

Overall, use common sense and if

The electrical system must have

being touched, maintained or

The mixers and their components

Shafts in the horizontal storage

The mixers are not a step and must

Overall, use common sense and if

Damage due to improper storage,

noted on the receiving documents

Make sure the more has the correct

Check the levelness of the mounting

If equipped with a protection plug, a

Check all exterior items on the

Uniformly tighten all nuts and bolts.

Make sure there is proper lubricant

Uniformly tighten the fasteners

In-tank fasteners include anti-

With water in the vessel (the mixer

assembly drawing). If not, re-wire

In general, we have had good

Type CF52 CF62 CF72 CF82 CF92 CF102 CF132

Table 2. Main parameters for CF series three-stage reducer

List of lubricating oil

-10 to + 15℃ -10 to +40℃

ISO VG150； ISO VG320；

List of lubricating oil supplier

ISO VG Shell BP Mobil ARAL Lotus

High quality lithium grease should

Supplier Lotus Shell Mobil BP

determine the cause. The mixer

Periodically check for loose

sure reservoirs are full on a regular

Section 7 – Preventive maintenance

Please see section 6.

Section 8 – Recommended spares

The end user must consider that

Impeller blades should always

The end user should contact Lotus

1. Oil level is too high 1. Discharge oil to appoint level

2. Connection face seal failed 2. Clean connection face and resealed

3. Bearing or other parts wearing 3. Change bearing and others part

4. Over loading 4. Reduce load

5. Vibration from gearbox 5. Run reducer by itself, check vibration source

Section 10 - Diagnosing Causes of Helical Gear Tooth Damage

In general, Lotus Mixers uses a special lock washer, which is intended to

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