Fristam pumps Fzx 2010 Instructions for use

InstructIon and MaIntenance Manual:

Powder MIxer (orIgInal InstructIons)

table of contents

1 Introduction �� 4

1�1 Description�� 4

1�2 Safety �� 4

1�3 Caution �� 4

1�4 Manufacturer Information �� 4

1�5 Scope of Supply �� 5

1�6 Scope of Documentation�� 5

1�7 General Information�� 5

1�8 Display Conventions�� 6

1�8�1 Safety Instructions�� 6

2 Safety �� 8

2�1 Intended Use �� 8

2�2 Predictable Misuse�� 8

2.3 System Specic Safety Instructions�� 8

2�4 Labels ��10

2�5 Noise Emissions ��10

2�6 Disposal��10

3 Design and Function��12

3�1 Principles of Design ��12

3�2 Funnel��14

3�3 Pipes ��14

3�4 Pumps��16

3�5 Control Panel ��16

3�6 Vibratory Motor (Optional)��17

3�7 Funnel Screen (Optional) ��17

3�8 Sizes and Standard Equipment ��18

3�9 Hydraulic Diagrams ��19

3�10 Function ��20

4 Transportation ��21

4�1 Safety Instructions ��21

4�2 Moving With Industrial Truck ��21

4�3 Moving With Crane��21

5 Storage��23

5�1 Safety Instructions ��23

5�2 Storage Conditions��23

5�3 Mothballing of the Powder Mixer ��23

5�4 Recommissioning��23

6 Installation ��24

6�1 Safety Instructions ��24

6�2 Installation Location��24

6�3 Reduction of Noise and Vibration��24

6�4 Powder Mixer Fixation ��25

6�5 Installation of Pipes��25

6�6 Supply System Connection��27

6�7 Hydraulic Connection��27

6�8 Connection of Power Supply ��28

6�9 Checking Direction of Rotation of Pumps��28

6�10 Cleaning��28

7 Operation ��31

7�1 Establish Liquid Flow��31

7�2 Mixing��31

7�3 Shutting Down the Powder Mixer ��33

8 Faults ��34

8�1 Safety Instructions ��34

9 Maintenance��35

9�1 Safety Instructions ��35

9�2 Replacement Parts ��35

9�3 FS Shear Blender Maintenance��36

9�4 FZX Liquid Ring Pump Maintenance ��36

9�5 FDS Twin Screw Pump Maintenance��36

9�6 Arc Valve Repair ��36

10 Appendix ��37

10.1 Specications ��37

10�2 Performance Overview��38

10�3 Lubricants��38

10�4 Troubleshooting Table ��39

10�5 Maintenance Intervals ��40

10�6 Replacement Parts ��40

10�7 EC Declaration of Conformity ��40

1 IntroductIon

1.1 descrIPtIon

This operator’s manual describes all sizes, models and versions of the Fristam PM 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 order related documents�

Fristam’s Powder Mixer provides quick, high-performance blending of wet and dry ingredients

into a uid stream. What makes Fristam’s Powder Mixer unique is its proven pump and blender

system that is efcient and easy to use.

The FZX Liquid Ring Pump creates consistent suction at the bottom of the funnel to prevent

plugging and maintain powder rate, even as viscosity increases�

The rotor-stator design of the FS Series Shear Blender eliminates unblended product and

prevents lumps and masses for consistent batch-to-batch repeatability�

More information on the Fristam Powder Mixer can be found online at:

https://www�fristam�com/pm

1.2 safety

This instruction and maintenance manual shall be read and completely understood prior to

operation of the powder mixer� The manual should be kept available at the powder mixer

installation location�

All applicable local/national regulation and laws shall be followed�

All work described herein may only be performed by qualied personnel.

Personal protective equipment (PPE) such as hearing protection may be required�

Despite inherent safe design measures, some amount of residual risk will remain� Throughout

the manual these risks will be pointed out�

1.3 cautIon

Begin all pump maintenance operations by disconnecting the energy source to the pump�

Observe all lock out/tag out procedures as outlined by ANSI Z224�1-1982 and OSHA 1910�147

to prevent accidental start-up and injury�

1.4 Manufacturer InforMatIon

Fristam Pumps USA

2410 Parview Road

Middleton, WI 53583 USA

Telephone: +1 (608) 831-5001

E-mail: sales@fristampumps�com

1.5 scoPe of suPPly

The package includes the following items:

• Powder Mixer Frame (Table)

• Removable Funnel

• Optional: rectangular offset hopper, vibrator, screen, lid, level probe, BBU adapter, jug

rinse, etc�

• Liquid Ring Pump type Fristam FZX or Double Screw Pump type Fristam FDS

• Shear Blender or Pump type Fristam FS or FSI

• Piping system with valves, inline sight glass, pressure gauges and connections

• Optional: actuated valve(s), FS bypass

• Control cabinet with switches, buttons and indicator lights

• Optional: VFD, vortec cooler, dry contacts

1.6 scoPe of docuMentatIon

Documentation includes the following items:

• This operator’s manual

• FZX Liquid Ring Pump or FDS Twin Screw Pump manual

• FS Shear Blender manual

• Circuit diagram for control panel

• Vibrator motor manual (optional)

• VFD brief manual (optional)

• Powder Mixer spec sheet

• FZX Liquid Ring Pump spec sheet

• FS Shear Blender spec sheet

• Customer requested documentation (complete list available upon request)

Documentation shipped with the Powder Mixer is typically located in a packet in the funnel

and/or control panel cabinet� Please read this information before installing and operating the

powder mixer�

Replacement documentation can be obtained from Fristam Pumps USA and/or downloaded

from the following website�

https://www�fristam�com/pm

1.7 general InforMatIon

Please read this operator’s manual completely before using the powder mixer and keep it

available at the mixer installation location�

Heed the applicable national regulations of the owner’s country and the company’s work and

safety regulations�

All work described here may only be performed by qualied experts with caution.

Danger of contamination: Heed legal and operational safety regulations when pumping or

lling dangerous media.

1.8 dIsPlay conventIons

List items are preceded by dots:

• Part 1

• Part 2

Handling instructions that must be performed in a specied order are numbered:

1� Step 1

2� Step 2

Handling instructions that do not need to be performed in a specied order are

preceded by triangular bullets:

∆Action

1.8.1 safety InstructIons

A safety instruction with the signal word “Danger” indicates personal hazards causing

death or serious injury�

A safety instruction with the signal word “Warning” indicates personal hazards that may

lead to death or serious injury�

A safety instruction with the signal word “Caution” indicates personal hazards that may

lead to mild to moderate injuries�

A safety instruction with the signal word “Notice” warns of the possibility of material

damage�

2 safety

2.1 Intended use

The standard PM powder mixer version is designed for use in the food, beverage, dairy,

personal care, pharmaceutical and biotechnology industries�

The PM powder mixer is designed for blending liquid base media with powder or liquid

additive media� In its standard use, the powder mixer is designed for batch mode with

individual powder bags� Continuous operation utilizing conveying equipment is possible with

additional engineering and equipment�

Each PM powder mixer is congured according to customer requirements. The seal materials

in the pumps have been selected for the respective media�

Supply and pumping of the base medium must be done in compliance with the maximum

temperatures and pressures specied for the given powder mixer version and size.

The pump ow direction for the self-priming pump is xed. The FZX pump can generate a

vacuum in the suction line�

The PM powder mixer may only be used under the operating conditions specied in the

customer’s order� See the attached Order-Related Documents� For other operating conditions,

please contact Fristam�

2.2 PredIctable MIsuse

• The standard PM powder mixer versions may not be used in explosive

atmospheres�

• Introduction and pumping of foreign objects in the mix can block and destroy

the pipes, valves or shear blender�

• Pumping of base media or powders other than those specied can destroy

pipes, valves or pumps� The seal materials (elastomers) and the pumps have

been selected for specic base media and mixtures. See the Order-Related

Documents�

• Pumping of powders other than those specied or incorrect mixing ratios can

clog the pipes, valves or pumps� For uninterrupted operations, the maximum

allowable particle size of the powder must not be exceeded�

2.3 systeM sPecIfIc safety InstructIons

Impermissible Pressure or Temperature Range

Personal injury and material damage from leakage or bursting of pumps or pipes and valves�

∆Maintain the pump, pipe and valve pressures within the specied pressure

ranges� See the operator’s manuals for the pumps�

∆Maintain the pump and pipe temperatures within the specied temperature

ranges� See the operator’s manuals for the pumps�

Hot Equipment Surface

Contact burns from touching the pipes�

∆Check the temperature before touching the pipes�

∆Only touch the pipes if you are wearing suitable protection�

Noise Generated by Running Powder Mixer

Permanent hearing damage� The A-weighted sound pressure level of the powder mixer

can be greater than 80 dBa�

∆Always wear ear protection in the vicinity of the running powder mixer�

∆The local noise exposure regulations must be complied with�

∆See the noise emission values for the pumps in the attached operator’s manuals�

Danger of Crushing When Moving Powder Mixer on Casters

Foot injuries from being run over by casters�

∆Wear safety shoes�

Cold Fireghting Water on Hot Pump

Material damage from bursting of pump�

∆Do not cool the pump down excessively when extinguishing a re.

Unsuitable Working Height or Direction

Danger of injury when working on raised table�

∆Lift the powder bag using a suitable aid�

∆Place a working platform beside the table and use�

∆Work on the side of the table designated for this purpose�

2.4 labels

∆Do not alter or remove the labels on the powder mixer or pumps�

∆Immediately replace damaged or lost labels with ones that are true to the

originals�

2.4.1 safety labels

“Do not remove guard” Indicates that the guards on the pump must not be removed

during operation�

2.5 noIse eMIssIons

The owner of the Powder Mixer must determine the respective sound pressure level for

the base media used and instruct and protect personnel accordingly�

Noise Generated by Running Pump

Hearing damage�

∆The local noise exposure regulations must be complied with� For noise emission

values for the pumps, please see the pump operator’s manuals�

Noise Generated by Running Vibratory Motor

Hearing damage�

Wear ear protection when using the powder mixer with pumps or shakers with

specied sound pressure levels of greater than 80 dBA. See Chapter 10.1.2, “Noise

Emissions,” and the operator’s manual for the vibratory motor�

2.6 dIsPosal

∆Follow the instructions in the operator’s manuals for the powder mixer

components�

2.6.1 dIsPosal of transPortatIon Package

∆Recycle the transportation package

2.6.2 dIsPosal of grease

∆Dispose of grease and objects saturated with grease in an environmentally

friendly manner in accordance with applicable regulations�

2.6.3 dIsPosal of lubrIcatIng oIl

∆Dispose of oil and objects saturated with oil in an environmentally friendly

manner in accordance with applicable regulations�

2.6.4 dIsPosal of Powder MIxer

1� Carefully clean the powder mixer� Dispose of residues in an environmentally

friendly manner in accordance with applicable regulations�

2� Dismantle the powder mixer into its constituent parts�

3� Dispose of the components in an environmentally friendly manner in accordance

with applicable regulations�

3 desIgn and functIon

3.1 PrIncIPles of desIgn

The key components of a PM Powder Mixer are a pump (P-1), a shear mixer (P-2), a

liquid control valve (V-2), a powder control valve (V-1), a pressure indicator (PI-1), a

funnel and a control cabinet� The components are mounted to a frame with a table top�

The entire system is mounted on casters or adjustable legs�

No. Part

C-1 Inlet Connection

V-2 Liquid Control Valve

PI-1 Inlet Vacuum Guage

V-1 Powder Control Valve

P-1 Pump

SG-1 Sight Glass

P-2 Shear Blender

PI-2 Discharge Pressure

Guage

F-1 Funnel

VIB-1 Funnel Vibrator

C-2 Outlet Connection

PI-1V-2

P-2

F-1

C-1 P-1

C-1 C-2PI-2

VIB-1

V-1

SG-1

3.2 funnel

Dry and liquid ingredients are poured into the removable funnel, where it is then

routed to the base uid in the pipes. The funnel is sealed in the lower region by

powder control valve (V-1)� Optional items include: vibratory motor, screen, CIP cover,

protective cover, etc�

• Electric funnel vibrator

• Pneumatic funnel vibrator

• Funnel screen

• Funnel cover

• CIP funnel cover

• Spray ball

• Rectangular hopper

• BFM tting lid for BBU

• High and/or low level sensors

3.3 PIPes

The pipes include connections, valves and the sight glass� Standard valves are supplied

with hand levers� Actuators are available for all valves�

The premix, made up of the base uid and the inducted powder and/or liquid, is

formed in the pipe region between liquid control valve V-2 and pump P-1�

The homogeneous end product is formed in the shear blender P-2 upstream of the

discharge-side connection�

3.3.1 valves

The manual valves in the base version are set as follows:

Buttery valves: depress thumb button and rotate to desired position.

Diaphragm valves: rotate bonnet to desired position

Arc valve: Pull handle out lengthwise and rotate to desired position

3.3.2 varIants of Powder control valve v1

• Manual Arc Valve

• Pneumatic Arc Valve (open/closed)

• Pneumatic Arc Valve with Positioner (0 – 100%)

• Manual Buttery Valve

• Pneumatic Buttery Valve (open/closed)

3.3.3 varIants of lIquId control valve v2

• Manual Diaphragm Valve

• Pneumatic Diaphragm Valve with Positioner (0 – 100%)

• Manual Buttery Valve

3.4 PuMPs

3.4.1 fZx lIquId rIng PuMP

For simple applications with highly soluble powders, like sugar or salt, only the FZX

liquid ring pump is needed to induct your solids�

Please locate the information in the FZX documentation�

https://www�fristam�com/fzx

3.4.2 fds double screw PuMP

The Fristam FDS allows the powder mixer to handle a wide range of viscosities, up

to 1,000,000 cps� Products can begin at lower viscosities and the FDS will maintain

consistent suction as the product concentrations and viscosities climb past the

point where traditional pumps would fail�Please locate the information in the FDS

documentation�

https://www�fristam�com/fds

3.4.3 fs shear blender/PuMP

As an inline blender, the Fristam’s FS blends products quickly and consistently� The

Shear Blender’s rotor-stator design eliminates unblended product and prevents lumps

and masses in product for consistent, repeatable results� The FS can also be installed

into your existing batch tank process line to rene your mix, simply and affordably.

Please locate the information in the FS Documentation�

https://www�fristam�com/fs

3.5 control Panel

The powder mixer is controlled via the attached control panel� A circuit diagram is

included with the PM documentation�

In some cases, the powder mixer is sold without a control panel and will be controlled

by an external system�

No. Element Function

1 FS On Button Starts FS Motor & Light Indicates Running

2 FS Off Button Stops FS Motor

3 FZX On Button Starts FZX Motor & Light Indicates Running

4 FZX Off Button Stops FZX Motor

5 VFD Control Pad (Optional) Allows for changing VFD parameters

6FZX Amp Readout Indicates current amp draw of FZX

7 Main Switch Disconnects power to Control Panel

8 Emergency Stop Button Quickly disconnects power to control panel

9 Vibrator Control Switch

(Optional)

Starts and stops electric vibrator motor

1

3

4

9

6 7

8

5

3.6 vIbratory Motor (oPtIonal)

The vibratory motor causes the funnel to vibrate and facilitates uniform powder ow to

the bottom of the funnel�

3.7 funnel screen (oPtIonal)

The funnelscreen helps to improve powder ow and prevents clumping in the funnel. It

catches clumps higher up in the funnel, where they can be broken up manually�

The screen may also help to prevent foreign materials from falling in the PM�

3.8 sIZes and standard equIPMent

The following versions of the powder mixer are available�

Depending on the application, other combinations of pumps and connections can be

used� The dimensions of the pipes and the connections may need to be adjusted for

the viscosity of the end product�

3.9 hydraulIc dIagraMs

3.9.1 Recirculation from Atmospheric Tank

No. Part

C-1 Inlet Connection

V-2 Liquid Control Valve

PI-1 Inlet Vacuum Guage

V-1 Powder Control Valve

P-1 Pump

SG-1 Sight Glass

P-2 Shear Blender

PI-2 Discharge Pressure Guage

F-1 Funnel

VIB-1 Funnel Vibrator

C-2 Outlet Connection

A (length)

B (width)

D (height to frame top)

E (funnel width)

C (height to funnel top)

Model FZX Model FS Model Inlet Outlet A B C D E

01-10 2010 712 1.5

(3.8)

1.5

(3.8)

56

(142)

30

(76.2)

36.5

(92.7)

34

(86.4)

12

(30.5)

10-52 2100 3522 2

(5.1)

2

(5.1)

71

(180)

30.5

(77.5)

40.5

(103)

38

(96.5)

24

(61)

15-52 2150 3532 2

(5.1)

2

(5.1)

71

(180)

30.5

(77.5)

41.5

(105)

38

(96.5)

24

(61)

20-53 2200 3532 2.5

(6.4)

2.5

(6.4)

83

(211)

30.5

(77.5)

41.5

(105)

39

(99.1)

24

(61)

25-53 2250 3532 2.5

(6.4)

2.5

(6.4)

83

(211)

30.5

(77.5)

41.5

(105)

39

(99.1)

24

(61)

2-52 FDS 2 3522 2

(5.1)

2

(5.1)

83

(211)

30.5

(77.5)

41.5

(105)

39

(99.1)

24

(61)

3-53 FDS 3 3532 3

(7.6)

2

(5.1)

104

(264)

35

(89)

45.8

(116)

43.2

(110)

24

(61)

All dimensions are in inches (centimeters).

3.10 functIon

The PM powder mixer is a system in which powder or liquid ingredients (e�g� sugar,

milk, cocoa powder, thickeners, oil, avoring, etc.) are introduced into or dispersed in a

base uid.

The liquid ring or double screw pump draws the base liquid from a tank and conveys

it through a short pipe to the shear blender� If the pump is throttled at the suction side

via the throttling valve, a vacuum (of up to 10” Hg) is built up between the throttling

valve and the pump� This is where the funnel with the inlet for the ingredients is

located�

The vacuum causes, for example powder or liquid to be drawn directly into the uid

stream� First this still inhomogeneous premix reaches the pump,, where it is premixed�

The premix is then pumped to the shear blender, where the remaining clumps are

completely broken up due to the high turbulence at tip speeds of up to 30 m/s�

4 transPortatIon

Transportation may only be performed by trained personnel� The pump may be moved

using approved lifting devices suitable for the weight/size of the pump� Improperly

securing the pump may result in injury from falling, tipping, or unsecured parts�

Dimensional information is available for download at www�fristam�com/usa� Weight

information is based on motor selection and is available upon request�

4.1 safety InstructIons

Rolling on Sloping Site

Injuries from being crushed or run over, material damage�

∆Ensure that the powder mixer is placed on a level surface�

∆Lock the casters�

∆Additionally secure the frame for operation�

∆Falling or Unsecured Parts

∆Danger of injury from impact or crushing�

∆Only use suitable means of conveyance and hoists� Information on powder

mixer weight can be found in the “Order-Related Documents”�

∆Before moving the powder mixer, secure it to prevent it from slipping

∆Secure pipes and attachment parts and check screwed connections�

∆Contamination, Impact, and Moisture

∆Damage to pipes, valves and pumps�

∆Removed the protective lm just prior to installation.

∆Remove the pipe tting covers just prior to connection to the pipes.

Fristam Pumps FZX 2010 Instructions for use

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