Fristam Pumpen PM User manual

Original Instructions
Powder mixer
PM
PM-V
PM-D
Powder mixer size:
Powder mixer no.:

Copyright
© Copyright 2020 Fristam Pumpen KG (GmbH & Co.)
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commercial purposes is prohibited.
The original version of this document is the German version.
All other language versions are translations of the original German version.

3
Table of contents
1 Introduction .......................................................... 5
1.1 Foreword.................................................................. 5
1.2 Manufacturer.......................................................... 5
1.3 Scope of delivery................................................... 5
1.4 Documentation ..................................................... 5
1.5 About this operator's manual........................... 6
1.6 Typographical conventions .............................. 6
2 Safety........................................................................ 7
2.1 Intended use........................................................... 7
2.2 Foreseeable misuse.............................................. 7
2.3 Machine-specific safety instructions.............. 7
2.4 Signs attached to mixer...................................... 9
2.5 Noise emissions ..................................................... 10
2.6 Disposal .................................................................... 11
3 Design and function.......................................... 12
3.1 Principle of design................................................ 12
3.2 Hopper...................................................................... 12
3.3 Pipes........................................................................... 13
3.4 Pumps ....................................................................... 14
3.5 Control cabinet (optional) ................................. 14
3.6 Vibration motor (optional)................................. 16
3.7 Screen (optional)................................................... 16
3.8 Protective grille (optional)................................. 16
3.9 Mixer sizes and standard equipment ............ 17
3.10 Hydraulic diagram ................................................ 18
3.11 Function ................................................................... 19
4 Transport................................................................ 19
4.1 Safety instructions ................................................ 19
4.2 Transporting powder mixer on industrial
truck........................................................................... 20
4.3 Transport by crane................................................ 20
5 Storage .................................................................... 21
5.1 Safety instructions ................................................ 21
5.2 Storage conditions ............................................... 21
5.3 Mothballing powder mixer ............................... 21
5.4 Recommissioning ................................................. 21
6 Installation ............................................................. 22
6.1 Safety instructions................................................. 22
6.2 Location of installation........................................ 22
6.3 Measures to reduce noise and vibration....... 22
6.4 Fixture of powder mixer...................................... 23
6.5 Installing and connecting pipes....................... 23
6.6 Connections............................................................. 24
6.7 Hydraulic connection........................................... 24
6.8 Connection of power supply............................. 25
6.9 Checking direction of rotation of pumps ..... 25
6.10 Cleaning.................................................................... 26
7 Operation................................................................ 28
7.1 Switching powder mixer on (mixer with
control cabinet)...................................................... 28
7.2 Starting powder mixer......................................... 28
7.3 Monitoring mixing operation ........................... 29
7.4 Switching powder mixer off .............................. 30
8 Faults......................................................................... 30
8.1 Safety instructions................................................. 30
9 Maintenance.......................................................... 31
9.1 Safety instructions................................................. 31
9.2 Spare parts ............................................................... 31
10 Appendix................................................................. 32
10.1 Technical data......................................................... 32
10.2 Power data ............................................................... 33
10.3 Lubricants................................................................. 34
10.4 Troubleshooting table......................................... 34
10.5 Maintenance intervals ......................................... 37
10.6 EC Declaration of Conformity............................ 38

//POWDER MIXER PM/PM-V/PM-D ///
4

5
1 Introduction
1.1 Foreword
This operator's manual describes all sizes, designs and versions of the PM-V/PM-D powder
mixer.
Information on the model, size, version, and accessories applicable to your powder mixer
can be found on the rating plate on your powder mixer and in the enclosed order-related
documents.
1.2 Manufacturer
FRISTAM Pumpen KG (GmbH & Co.)
Kurt-A.-Körber-Chaussee 55
21033 Hamburg
GERMANY
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
1.3 Scope of delivery
The delivery includes the following items:
– Table
– Adjustable machine feet or casters
– Hopper
Optional: Protective grilles, screen, guard or CIP cover, screw-in bushing for fill level sen-
sor, vibration motor
– Feed pump
– Shear pump type Fristam FSP
– Piping system with valves, pressure gages, inline sight glass, and connections
Optional: Adapter, pneumatic or electro-pneumatic valve actuator, bypass, pressure
transducer
– Other optional equipment:
Control cabinet with switches, buttons, indicators; frequency converter with control pa-
nel, connecting cable and CEE three-phase plug according to DIN EN 60309.
1.4 Documentation
The documentation includes the following items:
– This operator's manual
– Technical data of powder mixer
– Operator's manual of feed pump (see Table 1 „Feed pump“)
– Operator's manual of FSP shear pump
PM PM-V PM-D
Centrifugal pump
FZ
Positive displacement pump
FL3
Double screw pump
FDS
Table 1 Feed pump

//POWDER MIXER PM/PM-V/PM-D ///
6
– Technical documentation for other components
– Order-related documents
– Circuit diagram of control cabinet (if applicable)
Please read the above documents before installing and operating the powder mixer.
1.5 About this operator's manual
Please read this operator's manual before using the powder mixer and keep a copy of the
manual available near the powder mixer.
Always comply with the applicable statutory regulations and the internal work and safety in-
structions.
All tasks described in this document must be performed by qualified technicians and with
the necessary caution.
Risk of contamination: When handling or processing hazardous substances, always comply
with the statutory safety regulations and internal safety instructions.
1.6 Typographical conventions
List items are preceded by dashes:
– Part 1
– Part 2
Tasks that must be performed in a specified order are numbered:
1. Switch device on.
2. Switch device off.
Tasks that do not need to be performed in a specific order are preceded by triangles:
►Action.
►Action.
1.6.1 Safety instructions
A safety instruction with signal word "Danger" indicates a hazard that causes death or seri-
ous injury.
A safety instruction with signal word "Warning" indicates a hazard that may cause death or
serious injury.
A safety instruction with signal word "Caution" indicates a hazard that may cause minor or
moderate injury.
A safety instruction with signal word "Note" warns of the risk of damage to equipment and
material.

7
2 Safety
2.1 Intended use
The powder mixer has been designed for applications where stringent hygiene standards
must be maintained, for instance in the food, pharmaceutical or biotechnology industries.
The powder mixer is intended for the blending of liquid base media with additives in pow-
der or liquid form. In standard use, the powder mixer is run to process individual batches of
powders supplied in bags. For continuous operation in conjunction with a conveyor system,
the machine must be upgraded accordingly.
Each powder mixer is designed and manufactured to customer requirements, and the
sealing materials are specifically selected to be compatible with the medium.
The supply and pumping of the base medium must be done in compliance with the maxi-
mum temperatures and pressures specified for the given powder mixer version and size. For
details, see enclosed technical data and information in the order documentation.
The pumps must be run exclusively in the specified direction of rotation. Otherwise, the va-
cuum required to suck in the powder cannot be produced.
The powder mixer must only be operated under the conditions specified in the order confir-
mation from Fristam. If the actual operating conditions deviate from those in the order con-
firmation, contact Fristam.
2.2 Foreseeable misuse
– The standard Powder mixer PM/PM-V/PM-D versions must not be operated in potentially
explosive atmospheres.
– The introduction and pumping of foreign bodies in the pumped medium can block and/
or destroy the pipes, valves, and pumps.
– Pumping base media or powders other than those specified above can destroy pipes,
valves and pumps. The seal materials (elastomers) and the pumps have been selected to
suit specific base media and mixtures. For details, see order documentation.
– For trouble-free operation, adhere to the specified particle size and flowability of the
powder, and the viscosity of the mixture (see order documents).
– Modifications to the powder mixer are only permissible with the consent of Fristam.
2.3 Machine-specific safety instructions
Inadmissible pressure and temperature range
Risk of injury and damage to property from leakage or bursting pumps, pipes and valves.
►Keep the pump, pipe, and valve pressures within the specified pressure and temperature
range. For details, see technical data of components and order documentation.
Hot surfaces
Risk of injury from burns when touching hot machine components.
►Before touching a component, make sure that it is not hot.
►Wear suitable protective gloves.

//POWDER MIXER PM/PM-V/PM-D ///
8
Noise emission from running powder mixer
Permanent hearing damage. The A-weighted sound pressure level of the powder mixer can
be higher than 80 dBA.
►When standing close to the running powder mixer, wear suitable hearing protection.
►Comply with the statutory noise exposure regulations.
►For noise emission values of pumps, see enclosed operator's manuals.
Risk of injury from crushing when moving powder mixer on casters
Injury to feet from casters.
►Wear safety footwear.
Firefighting with cold water
Risk of damage to components from bursting.
►When extinguishing a fire, avoid temperature shocks to components by cold water.
Unsuitable working height and direction
Risk of injury when working on raised table.
►To lift the powder bag, use suitable aids.
►Place a working platform beside the table and work from the platform.
►Work on the side of the table designated for this purpose.
Handling big bags
Risk of injury from heavy loads.
►To lift and move big bags, use suitable frames/equipment to be provided on site.
►Do not place the weight of big bags on the powder mixture.
Automatically actuated valves
Risk of injury from moving valve components.
►Protect automatically actuated valves with suitable guards.

9
2.4 Signs attached to mixer
►Do not alter or remove the signs attached to the powder mixer.
►Replace damaged or missing signs without delay.
2.4.1 Safety signs
Fig. 1 “Hot surface"
The "Hot surface" sign indicates that parts of the machine might become hot during operati-
on or that a hot base medium might be pumped. Before touching a component, make sure
that it is not hot. Wear suitable protective gloves.
Fig. 2 "Do not reach into hopper"
The "Do not reach into hopper" sign indicates that it is forbidden to reach into the hopper
while the mixer is running. There is a risk of injury from the valve.
Fig. 3 "Do not bend over hopper"
The "Do not bend over hopper" sign indicates that breathing in dust or aerosols escaping
from the hopper must be avoided. Dust and aerosols can irritate the respiratory tract. If re-
quired, wear a dust mask.
If the machine is incorrectly operated, there is a risk that liquid escapes at high pressure from
the hopper, causing injury.
Fig. 4 "Do not place small parts in hopper"
The "Do not place small parts in hopper" sign indicates that it is forbidden to place small, so-
lid parts such as rocks or metal components in the powder mixer, as they might damage or
even destroy pumps and other components, and contaminate the product. In an emergen-
cy, press the emergency stop button and remove small parts from the mixer.
Fig. 5 "Wear hearing protection"
The "Wear hearing protection" sign indicates that there is a risk of damage to hearing from
high noise emissions. While the powder mixer is in operation, wear hearing protection.

//POWDER MIXER PM/PM-V/PM-D ///
10
2.4.2 Rating plate
The rating plate is attached to the frame beside the shear pump.
Fig. 6 Rating plate
2.5 Noise emissions
It is the responsibility of the machine owner to determine the actual sound pressure level on
site and to take suitable measures to protect personnel, through instruction and the provisi-
on of protective equipment.
Noise generated by running pump
Risk of damage to hearing
►Comply with the statutory noise protection regulations. For noise emission values of the
pumps, refer to the respective operator's manuals.
Noise generated by running vibration motor
Risk of damage to hearing
►Powder mixers with two hoppers or multiple vibration motors might generate higher
noise emissions.
When operating the powder mixer with pumps or shakers whose specified sound pressure
level is above 80 dBA, wear hearing protection. See "Kapitel 10.1.2 „Noise emissions“, Seite 32"
and the operator's manual of the vibration motor.
1Manufacturer
2Type: Powder mixer
3Serial no.: Serial number of powder mixture
4P: Motor power (total) [kW]
5 Year of manufacture
6mges: Mass (total) [kg]
7CE Mark
5
1
2
3
7
6
4

11
2.6 Disposal
►Observe the instructions in the operator's manuals of the various powder mixer compo-
nents.
2.6.1 Disposing of transport packaging
►The transport packaging can be recycled.
2.6.2 Disposing of grease
►Dispose of grease and implements contaminated by lubricants according to the statuto-
ry waste disposal regulations.
2.6.3 Disposing of lubricating oil
►Dispose of oil and implements contaminated by lubricants according to the statutory
waste disposal regulations.
2.6.4 Disposing of powder mixer
1. Clean the powder mixer. Dispose of residue according to the statutory waste disposal re-
gulations.
2. Dismantle the powder mixer into its constituent parts.
3. Dispose of the individual components according to the statutory waste disposal regulati-
ons.
2.6.5 Disposing of electrical and electronic waste
►Dispose of electrical and electronic waste according to the statutory waste disposal regu-
lations.

//POWDER MIXER PM/PM-V/PM-D ///
12
3 Design and function
3.1 Principle of design
The powder mixture includes a feed pump (P1), a shear pump (P2), and a hopper connected
to a piping system. The components are mounted on a table with a base frame. The hopper
can be equipped with an optional vibration motor. The entire system stands on casters or
feet.
Fig. 7 Components of powder mixer
3.2 Hopper
Powder or liquid additive media is poured into the hopper from where it is added to the
base medium in the pipe. The hopper is sealed by the metering valve V1 at its bottom outlet.
Other optional equipment includes protective grilles, filters, CIP covers, screw-in bushings
for fill level sensors and vibration motors.
12
3
5
4
9
10
678
1 Hopper, protective grille (optional)
2 Table
3 Vibration motor (optional)
4 Feed pump P1 (FZ, FL, FDS)
5 Control cabinet (optional)
6 Shear pump P2 (FSP)
7 Machine feet/casters (optional)
8 Frame
9 Pipes
10 Powder inlet

13
3.3 Pipes
The pipe system includes fittings, a pressure gage, manual and pneumatic valves, and the
sight glass. The manual valves are equipped with manually operated levers as standard. The-
se levers can be locked in the 0° and 90° positions. Other levers or actuators are available as
options.
The premix made up of the base medium and the powder or added liquid is formed in the
pipe section between the throttle valve V2 and the feed pump.
The homogeneous end product is produced by the shear pump P2 upstream of the dischar-
ge-side connection.
Fig. 8 Pipe system, version with manual valves
3.3.1 Valves
The manual valves in the standard version are set as follows:
1. Pull the lever out.
2. Rotate the lever to the desired position.
3.3.2 Metering valve V1
The metering valve V1 is a manual valve and equipped with a continuously adjustable lever.
As an option, V1 can be equipped with an electro-pneumatic actuator controlled with an 4-
20 mA input signal.
3.3.3 Throttle valve V2
The throttle valve V2 can be equipped with a continuously adjustable hand lever.
As an option, V2 can be equipped with an electro-pneumatic actuator controlled with an 4-
20 mA input signal.
1 Metering valve V1
2 Discharge-side connection
3 Suction-side connection
4 Throttle valve V2
5 Sight glass
6 Discharge valve V3
4
1
2356

//POWDER MIXER PM/PM-V/PM-D ///
14
3.3.4 Discharge valve V3
The discharge valve V3 is a manual valve with a standard lever that can be set to positions
"open" and "closed".
As an option, V3 can be equipped with an electro-pneumatic actuator opening and closing
the valve.
3.4 Pumps
3.4.1 Feed pump
The FZ (or FL3 or FDS) series feed pump draws in the supplied base medium and conveys
the premix through a short pipe to the shear pump.
In conjunction with the throttle valve V2, the pump produces the vacuum necessary to take
in the powder or additive from the hopper to mix it with the base medium.
Observe the instructions in the enclosed feed pump documentation.
3.4.2 Shear pump
The FSP series shear pump acts as a rotary homogenizer. It whirls the premix of base medi-
um and powder, and completely breaks down the remaining clumps with the help of high
turbulence and high circumferential speeds.
Observe the instructions in the enclosed FSP pump documentation.
3.5 Control cabinet (optional)
The powder mixer is controlled and monitored by means of the control and display ele-
ments on the control cabinet.
The pump drives are operated with a star delta starter or a frequency converter. The (optio-
nal) sensors and actuators are connected to the terminals in the control cabinet, so that they
can be easily integrated into the on-site control system.
The circuit diagram can be found in the control cabinet.

15
Fig. 9 Control cabinet (example)
In mixers with FC control, buttons 1 and 2 respectively switch on the power supply to the
frequency converter.
In such models, the control cabinet is fitted with start/stop buttons for the respective
pumps, potentiometers for speed selection, and control panels, if required.
No. Element Design Function
1 Switch for shear pump Rocker switch with indicator
light
Switching shear pump on/off
2 Switch for feed pump Rocker switch with indicator
light
Switching feed pump on/off
3 Vibration motor switch Selector switch with set
positions or selector dial
Switching vibration motor on/off
4 Fault indicator Indicator light Lights up when a fault occurs (see
"Faults")
5 Main switch Selector dial Switching powder mixer on/off
6 EMERGENCY-STOP but-
ton
Impact button Switching powder mixer off in an
emergency
7 Display and control
panel for frequency
converter (optional)
Panel with LCDs, buttons
and controls
Control of frequency converter
8 Setpoint potentiome-
ter (optional)
Control dial Adjusting pump setpoint speed
Table 2 Control and display elements at control cabinet
10
9
1234
7
5
6
8

//POWDER MIXER PM/PM-V/PM-D ///
16
3.6 Vibration motor (optional)
The vibration motor causes the hopper to vibrate and facilitates steady powder flow towards
the hopper base.
If the vibration motor is activated, it runs at specified switching cycles.
3.7 Screen (optional)
Various screens for installation in the hopper are available. Screens improve the powder flow
in the hopper and prevent the powder from clumping.
Depending on the application, screens also make it easier to fill the hopper.
Fig. 10 Hopper with grille
3.8 Protective grille (optional)
Powder mixers with an automatic valve V1 are equipped with a protective grille. It prevents
access to the valve whose settings cannot be changed by the operator. The protective grille
is permanently mounted in the hopper above the valve.
1 Hopper
2 Screen (optional)
3 Metering valve (here: disc valve)
1
2
3

17
3.9 Mixer sizes and standard equipment
The following standard version of the powder mixer are available:
Size Centrif.
pump
Power Shear pump Power Approx.
dimensions
Connection Approx.
weight
[kW] [kW] H/W/L [mm] DIN 11851 [kg]
PM01 FZ 15 PM
KD
2.2...4.0 FSP 712 VD 4.0...5.5 800
1000
1200
DN40 250
PM02 FZ 17 PM
KD
4.0...5.5 FSP 3522 VD 4.0...11.0 800
1000
1700
DN50 300
PM03 FZ 20 PM
KD
5.5...11.0 FSP 3532 VD 7.5...18.5 800
1000
1700
DN50 350
PM04 FZ 22 PM
KD
11.0...15.0 FSP 3542 VD 15.0...30.0 1050
1000
2050
DN65 450
PM05 FZ 25 PM
KD
15.0...18.5 FSP 3552 VD 22.0...45.0 1050
1000
2050
DN80 620
Table 3 PM powder mixer sizes
Size Displ.
pump
Power Shear pump Power Approx.
dimensions
Connection Approx.
weight
[kW] [kW] H/W/L [mm] DIN 11851 [kg]
PM-
V01
FL2 75 L3 2.2…4.0 FSP 712 VD 5.5…7.5 900
1000
1800
DN40 300
PM-
V02
FL2 75 L3 4.0…5.5 FSP 3522 VD 7.5…11.0 900
1000
1800
DN50 350
PM-
V03
FL2 75 L3 5.5…7.5 FSP 3532 VD 11.0…22.0 1000
1100
2000
DN50 400
PM-
V04
FL2 100 L3 5.5…7.5 FSP 3542 VD 22.0…37.0 1000
1200
2000
DN80 550
PM-
V05
FL2 100 L3 7.5…11.0 FSP 3552 VD 37.0…75.0 1000
1200
2000
DN100 720
Table 4 PM-V powder mixer sizes
Size Double
screw pump
Power Shear pump Power Approx.
dimensions
Connection Approx.
weight
[kW] [kW] H/W/L [mm] DIN 11851 [kg]
PM-
D01
FDS 1 U 1.1…5.5 FSP 712 VD 2.2…7.5 900
900
1500
DN50 depending
on FDS type
and motor
PM-
D02
FDS 1 U or
2U
3.0…7.5 FSP 3522 VD 4.0…11.0 1000
1000
2000
DN65 depending
on FDS type
and motor
PM-
D03
FDS 2 U or
3U
5.5…15 FSP 3532 VD 11.0…30.0 1150
1200
2200
DN80 depending
on FDS type
and motor
PM-
D04
FDS 3 U or
4U
11…37 FSP 3542 VD 15.0…45.0 1150
1200
2200
DN100 depending
on FDS type
and motor
Table 5 PM-D powder mixer sizes

//POWDER MIXER PM/PM-V/PM-D ///
18
Depending on the application, other combinations of pumps and fittings can be used. The
dimensions of the pipes and fittings may vary, depending on the application (throughput ra-
te, viscosity, etc.).
3.10 Hydraulic diagram
The feed pump P1 takes the base medium from the tank B1 and transfers it to the powder
mixer. By throttling the valve V2, a vacuum is produced. This helps suck the powder or addi-
tive from the hopper.
The powder flow can be controlled with the metering valve V1. The resulting premix is fed
by the fed pump P1 to the shear pump P2
where the mixture is homogenized. Subsequently, the finished mixture is discharged
through the powder mixer's discharge connection.
Depending on the product, circulation through the tank B1 might be required to improve its
homogeneity.
Fig. 11 Hydraulic diagram
54
12
36879
10
11
1 Scope of delivery of powder mixer
2 Tank B1 with base medium
3 Suction-side connection
4 Throttle valve V2
5 Pressure gage
6 Metering valve V1
7 Feed pump P1
8 Sight glass
9 Discharge valve V3
10 Shear pump (FSP) P2
11 Discharge-side connection

19
3.11 Function
The powder mixer is a system in which powder or liquid ingredients (e.g., sugar, milk pow-
der, cocoa powder, thickeners, oils, flavorings, etc.) are added to and dispersed in a base me-
dium solution.
The feed pump draws in the base liquid from a tank and conveys it through a short pipe to
the shear pump. As the throttle valve upstream of the feed pump is throttled, a vacuum is
produced in the section between the valve and the pump This is the section where the hop-
per containing the additive connected to the system.
The vacuum sucks the powder or liquid from the hopper into the liquid flow. The premix,
which at this stage tends to be in homogeneous, enters the feed pump where it is premixed
before it is transferred to the shear pump.
In the shear pump, any remaining clumps are dissolved by high turbulence and circumferen-
tial speeds.
In the process, a perfectly homogeneous mixture is produced.
4 Transport
The mixer must be transported by instructed personnel.
The powder mixer can be moved on an industrial truck or by crane.
Always transport the powder mixer in its installation position.
4.1 Safety instructions
Rolling away on slope
Risk of injury from crushing, risk of damage to property.
►Ensure that the powder mixer is placed on a level surface.
►Apply the caster brakes.
►Before operation, secure the frame.
Falling parts
Risk of injury from impact or crushing.
►Use only suitable transport equipment and slings. The weight of the powder mixer is spe-
cified in the enclosed documentation and printed on the rating plate attached to the mi-
xer frame.
►When transporting the powder mixer, secure it to the vehicle or hoist to prevent it from
becoming dislodged.
►Secure the pipes and attachment parts, and check fittings.

//POWDER MIXER PM/PM-V/PM-D ///
20
Contamination, impact and moisture
Risk of damage to pipes, valves and pumps.
– Prior to installation, remove the protective foil.
– The pipe fitting covers must only be removed just before connecting the pipes.
4.2 Transporting powder mixer on industrial truck
Preparation
►If the powder mixer is placed on a pallet, ensure that it is properly secured.
Procedure
1. Lift the powder mixer (pallet) with the forks of the industrial truck.
2. Carefully transport the powder mixer (pallet) to the new location and lower it to the floor.
4.3 Transport by crane
Falling parts
Risk of fatal injury from crushing, risk of damage to property.
►Only use slings that are designed for the total weight of the powder mixer.
►Ensure that no persons are standing under the lifted powder mixer.
Swaying parts
Risk of serious injury from crushing.
►Start and stop the crane with powder mixer smoothly.
►Ensure that no persons are standing within the danger zone of the powder mixer.
Auxiliary equipment
Slings: round slings approved in accordance with DIN EN 1492-1 and 1492-2.
Procedure
1. Wrap the round sling twice around the frame of the powder mixer.
2. Guide both loops of the sling to the crane hook and rotate by 180° to ensure that they
cannot slip from the hook.
3. Taking into account the center of gravity, secure the powder mixer in a horizontal positi-
on.
4. Lift the powder mixer.