Fusion Flow FG-P User manual

O&M
Operation and Maintenance Manual for Fusion
“Flow” series TOP ENTRY open tank mixers
Models FG-P, FR-P, & FW-P

Contents
Safety…………………………………………………………………………1
Inspection………………………………………………………………….....2
Storage………………………………………………………………………..2
Installation……………………………………………………………….…2-6
Maintenance………………………………………………………………..6-7
Warranty……………………………………………………………………....8
Contact Info……………………………………………………………….…..8
Section 1 – Safety

Safety should be one’s main priority when working with industrial mixing equipment.
There are many potential hazards associated with rotating equipment. The precautions
mentioned in this manual are not intended to cover all hazards in a plant or on this
equipment. Using safety mechanisms requires the constant attention of anyone in the
vicinity of this or any other equipment. Please use common sense and caution. DO
NOT attempt to operate this or any equipment if it does not appear safe. In addition,
please use all necessary personal safety devices as well as mechanical safety devices
when operating and or maintaining this or any equipment.
PLEASE READ BEFORE INSTALLATION / OPERATION
•Read this manual completely before operating the mixer. In addition to this
manual, please read manuals for all components. A manual for you motor and
gearbox will be available on-line from the manufacture of each component.
Nameplates are intentionally left on the units so you can find this information. If
you have difficulty locating this information, contact Fusion Fluid Equipment and
we will find it for you.
•Installation, operation, and maintenance should only be performed by qualified
personnel.
•Check all safety devices prior to starting the equipment. Do not operate the
mixer if those devices are not present. Do not operate the mixer if the devices
are not functional.
•BEFORE doing any maintenance on the mixer, disconnect all power. Be sure to
follow correct lock out – tag out procedure before proceeding.
•DO NOT touch any rotating parts under any circumstances. Keep all guards and
safety devices installed.
•Maintain the equipment on a regular basis. Unmaintained equipment can
become unsafe.
•Develop a safety checklist to ensure that proper caution is used during operation
and maintenance
•Do not modify your equipment without consulting the factory. Modification of the
equipment my cause the equipment to become unstable. In addition, it may
decrease the performance or mechanical stability.

Caution: There are several pinch points on these mixers
Section 2 - Inspection
Inspection should be done upon receipt of the mixer as well as before installation and
during maintenance.
1. Check to make sure that all components were received. Fusion Side Entry
mixers may be shipped in multiple packages. Typically your shipment should
contain:
•Mixer drive
•Gearbox
•Shaft
•Impeller hub and blades
2. Check to see if the equipment is damaged. Check the shaft to see if it appears
bent. Check the impellers to see if the blades appear abnormally bent. All of the
blades should be symmetrical. The equipment should not appear damaged in
any way.
3. Inspect the bore in the gearbox if shaft is shipped loose. It should be free of
galling or burs. Inspect couplings and hubs to make sure they are free of dings
and dents on mating faces. Check the mixer shaft to assure that it is straight and
free from galling on mating surfaces. If you proceed to install the mixer shaft with
these defects, the shaft may bind or vibrate and cause further damage, which
may not be covered under warranty. It may also be unsafe to operate.
Section 3 – Storage
Mixer should be stored into a cool, dry environment. Humid conditions can damage the
motor windings, output bearings, and lubrication. All of these factors may deteriorate
your mixer. Do not store the mixer near vibrating machinery. For long storage periods,
rotate the mixer shaft once a month and change gearbox lubricant before installation.
Section 4 – Installation
Before any actual installation, come up with a plan for mounting location. Mounting the
mixer on an angle according to the figure below will result in the best mixing
performance. Also, be sure that your tank is strong enough to handle the weight and
dynamic loads from the mixer. Please reference the approval drawing for these loads.
If you do not have them, contact your Fusion rep to obtain them. Fusion is not
responsible for damage done to the tank or injury to persons due to inadequate tank

design. Be sure that the anchor supports for the tie rods are sturdy enough to hold the
weight of the mixer. The flange alone is not enough to support this mixer! If the
mixer is supplied with a support leg, be sure that there is an adequate structural pad
underneath that will not settle.
Mounting Guideline For TOP Entry Mixers
On Center with Baffles – THE BEST WAY!
Other Mounting Options:
PLEASE BE SURE THAT YOUR MIXER IS DESIGNED FOR THIS CONDITION!
1. Off center – vertical: Mixers can be mounted in a vertical position 1/3 to ½ X tank
radius off center. Be sure that your custom drawing notes this. Mixers must be
specifically designed for this mounting condition. If you mixer was designed to only run
on-center with baffles, than mixer failure may occur. Please obtain verification from
Fusion that this mounting position is acceptable. In addition, make sure that the
impellers have AT LEAST 4” of clearance from the tank side wall during rotation.
2. Angle Offset: Angle offsetting the mixer is another acceptable mounting position to
promote proper performance. There are a few steps that MUST be taken to ensure
proper performance. As with “vertical offset” mounting, the mixer must be designed to
handle the condition. In addition, there are only a few ways to orient the gearbox so
that gear lubrication is not compromised. Please call Fusion to get a 3D layout of your
application done in order to properly angle mount your mixer.

Caution: There are several pinch points on the mixers
2. Mount the mixer to the desired location. Be careful, as there are several pinch
points in the mounting hardware, couplings, hubs, etc. Once the desired position
and mounting angles are achieved, tighten all of the hardware to the torque
specifications in the table below. THERE IS ONE EXCEPTION. The socket head
cap screw that holds the mixer shaft in the gearbox should not exceed half of the full
rated torque. Otherwise, please adhere to the specifications below:
Hardware Size Grade 2 and 300 series
stainless hardware
High strength grades 5
&8
¼” 5 ft*lbs 7 ft*lbs
5/16” 9 ft*lbs 14 ft*lbs
3/8” 15 ft*lbs 25 ft*lbs
½” 37 ft*lbs 60 ft*lbs
9/16” 53 ft*lbs 88 ft*lbs
5/8” 74 ft*lbs 120 ft*lbs
¾” 120 ft*lbs 200 ft*lbs
7/8” 190 ft*lbs 302 ft*lbs
1” 282 ft*lbs 466 ft*lbs
3. Mixer shaft installation: To avoid binding in the future and ease of installation,
apply process compatible grease or anti-seize compound on the end portion of the
mixer shaft, as well as the keyway. Be sure to slide the shaft into the bore slowly
and gently. The tolerances are very tight to keep concentricity and limit vibration. If
the shaft is forced, it will gall and the mixer will be damaged. Light tapping from a
plastic mallet may be required for large diameter shafts to slide the shaft into the
hollow bore.
Slide shaft into bore until it stops against the snap ring. The snap ring is there to
locate the position of the shaft. Once the shaft is in place, install the cap plate and
tighten the supplied socket head cap screw to ~half of the full torque value. See the
figure below for more detail:

4. Pre-Lubrication: Make sure that all grease fittings are lubricated on the motor,
gearbox, and pedestal. On larger units, the input bearing on the gearbox comes
with an automatic lubricator, which needs to be activated before use. See the
figures below for more detail:
A. Remove protective cap B. Activate lubricator per instructions inside
5. Impeller installation: Install the impeller hub on the shaft. If the hub “ears” have
a taper on them, the widest part of the ear should face away from the gearbox.
Tighten the set screw on the hub to the proper torque value. Install the blades on
the hub. The blades should be bolted on the face of the “ears” furthest away from
the gearbox. Tighten the hardware to the specified torque values. Please see the
picture below for orientation:
6. Electric Components: All wiring of motors, VFD’s, panels, and controls should be
done according to local code. If any wiring was provided by Fusion, please have
your electrical inspector inspect all connections, conductors, etc. to verify that the
installation is acceptable. Unless specifically requested, pre wiring of components
may not be UL approved. Call your local inspector!
Electric motors: Motors provided are specific to each application. You will be
able to locate the motor model number and MFG on the tag. You can find
performance data and operating limitations online. Otherwise, contact Fusion,
and we will provide this information to you.

NOTE: Wire so impeller rotates clockwise when viewed from behind
the gearbox
Section 5 – Maintenance
Warning: Turn off power to the mixer before any maintenance
1. Lubrication is the most important key to prolonging the life of your mixer. Be
sure to regularly grease all fittings on the mixer. Gearboxes units come pre-
lubricated with ISO VG220 mineral based oil, which is good for temps from 20
deg F to 140 deg F or Mobile SHC630 (-30F to 176F). Periodically remove
the vent plug to check for water contamination in the oil. Change the oil if
there is water contamination. Below is a list of recommended oils for this unit:

2. For harsh, washdown, or wet environments, special attention is required.
These units are provided with additional o-rings and lip seals to prevent
contamination from entering or leaving the drive. High pressure washing can
allow water to enter through the seals. Check for water contamination as
described in step 1 and also regularly remove motor drain plugs to remove
any water. Water contamination will greatly reduce the life of your mixer.

Section 6 – Warranty and Contact
Warranty:
All equipment or parts covered by this manual are guaranteed free from defective
material and workmanship for a period of twelve (12) months from date of shipment,
under normal use and service. This warranty does not cover failure of normal wear parts
unless the failure of such part has resulted from defective material and workmanship.
Fusion Fluid Equipment LLC will repair or replace, at its option, any equipment which
has been found to be defective and is within the warranty period, provided that the
equipment is shipped, with previous factory authorization, freight prepaid, to Fusion's
plant in Whitehall, Michigan, USA. All return shipments are made FOB Fusion's factory.
Fusion Fluid Equipment LLC is not responsible for removal, installation, or any other
incidental expenses incurred in shipping the equipment to or from Fusion Fluid
Equipment LLC. In the case of components purchased by Fusion Fluid Equipment LLC,
and incorporated in the equipment, the component manufacturer's guarantee shall
apply. NOTE: Any modifications or corrective work done to the equipment which were
not specifically authorized in writing by Fusion Fluid Equipment LLC shall void this
limited warranty, and Fusion Fluid Equipment LLC shall accept no liability for any of the
corrective work or expenditures which were conducted without their prior, written
authorization. Fusion Fluid Equipment LLC shall not be held liable for any further cost,
expense, or labor to replace equipment or replaceable parts, or indirect or
consequential damages.
With the exceptions of the limited warranty set out above, there are no other
understandings, agreements, representatives, or warranties implied (including any
regarding the merchant-ability or fitness for a particular purpose), not specified herein,
respecting this agreement or equipment, hereunder. This contract states the entire
obligation of Fusion Fluid Equipment LLC in connection with this transaction.
Contact:
For questions, concerns, or comments, we strongly recommend contacting the sales
representative that supplied your equipment. Otherwise your may email us or visit our
website. We typically respond same day.
Website:
www.fusionfluid.com
Email:
[email protected]
Thank you for choosing Fusion. We look forward to a long standing relationship with
you, providing high quality custom equipment!