FBM20, FBMX20 Submersible Basin Mixer- Brochure

NOTE To the installer: Please make sure you provide this manual to the owner of the equip ment or to the responsible party who maintains the system.FBM20 / FBMX20SUBMERSIBLE BASIN MIXERINSTRUCTION AND REPAIR MANUALForm #FM-03-538 | Part # 05625-548-1 | © 2012 Pentair Ltd. | 12/26/12 Fairbanks Nijhuis™ 12/26/12FBM20 / FBMX20 Submersible Basin MixerInstruction and Repair Manual2GENERAL INFORMATION:Thank you for purchasing your Fairbanks Nijhuis product. To help ensure years of trouble-free op er a tion, please read the fol low ing manual carefully.WARNING:Only qualified personnel shall install or service this product.CALIFORNIA PROPOSITION 65 WARNING:WARNING:This product and related accessories contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.BEFORE OPERATION:Read the following in structions care ful ly. Reasonable care and safe meth ods should be practiced. Check the local codes and requirements before installation.ATTENTION:This manual contains important information for the safe use of this product. Read this manual completely before using this product and refer to it often for con tin ued safe product use. DO NOT THROW AWAY THIS MAN U AL. Keep it in a safe place so that you may refer to it often.WARNING: Before handling electrical equipment, always disconnect the power first. Do not smoke or use sparkable electrical devices or flames in a septic (gaseous) or possible septic sump.CAUTIONS AND WARNINGS:HAZARDOUS LOCATIONS SERVICE:These mixers are to be used for handling sewage, wastewater and storm water only. DO NOT use in other hazardous locations. These motors must be repaired and serviced only at Fairbanks Nijhuis Authorized Service Centers or at the factory. Any unauthorized field repair voids the warranty, the hazardous locations rating, and Factory Mutual approval.CAUTION:To reduce risk of electrical shock, disconnect power before servicing this product.WARNING:See installation and service manual for proper installation.WARNING:To reduce risk of electrical shock, mixer is provided with grounding wire. Be certain that it is connected to ground.WARNING:Hazardous moving parts. To reduce the risk of injury, disconnect power before servicing the product.CAUTION:To reduce risk of electrical shock, DO NOT remove cord or strain relief. DO NOT connect conduit to mixer. Electrical installations shall be in accordance with the National Electrical Code and all applicable local codes and ordinances.For use with maximum 140°F water.Septic tank should be vented in accordance with local plumbing codes and should not be installed in locations classified as hazardous, in accordance with the National Electrical Code, ANSI/NFPA 70-1999.Fairbanks Nijhuis™12/26/12FBM20 / FBMX20 Submersible Basin MixerInstruction and Repair Manual3CAUTION:Risk of electrical shock. Do not remove cord and strain relief.WARNING:Severe injury may result from accidental contact with moving propeller. Keep clothing, hands and feet away from propeller any time power is connected to the mixer.CAUTION:Never work on mixer with power on. Make sure that the ground wire is securely connected and that the unit is properly grounded in accordance with local codes.THE MIXER:DESCRIPTION:The Fairbanks Nijhuis product cov ered by these instructions is a submersible basin mixer.The integral stain less steel motor shaft is sealed by two me chan i cal seals with an oil chamber between the seals to pro vide lubrication for both seal faces.Two ball bearings are used to handle the loads. The upper bearing takes radial load, while the larger lower bearing handles both thrust and radial loads. Both bearings are permanently lu bri cat ed by the dielectric oil in the motor housing. The motor is fixed within the motor housing and is com plete ly submerged in the di elec tric oil for maximum heat transfer. The motor housing and seal cham ber are com pletely sealed with O-rings located at mating part faces.The power cord entry system is designed to give double seal ing. The chamfered pilot of the motor housing mates with the molded cord end to form the first seal. The cord grip forms the second seal around the molded cord end and provides strain relief. The ca ble includes the leads for both heat sensors (motor protection) and the seal sen sor lead for seal leakage de tec tion.APPLICATION:The submersible basin mixer is used to break up crusts and solids that float at the top of a solids-handling basin. The unit can also be used for mixing and stirring applications in industrial areas and waste management facilities.RECEIVING MIXER:Inspect mixer on arrival for possible con cealed damage in shipping. Any dam age should be reported im me di ate ly to delivering carrier. Claims for damage must orig i nate at the re ceiv ing end. Claims for shipping damage cannot be processed at the factory.CODES:All local wiring codes must be observed. Consult the local inspector before in stal la tion to avoid costly delays that can occur due to rejection after job is finished.MIXER INSTALLATION:LOCATION:If mixers are installed in an existing basin or concrete sump, they may either be connected permanently or rails and brackets can be fur nished for mounting to walls of basin. The complete factory built packaged system is recommended for the most satisfactory in stal la tion and generally for the low est cost where expensive in stal la tion labor is involved.ELECTRICAL CONNECTIONS:Make all connections from motor to control panel to com ply with local codes.NOTE: Fairbanks Nijhuis built control panels supply the correct circuitry for moisture and heat sensor connections. Failure to install the correct circuitry with proper connection would negate warranty and Factory Mutual approval.Fairbanks Nijhuis™ 12/26/12FBM20 / FBMX20 Submersible Basin MixerInstruction and Repair Manual4MOTOR WIRING DIAGRAMSNOTE: Probe test resistor is used on FBMX20 UL Hazardous Location only.REDREDREDBLACKYELLOWGREENGREENYELLOWBLACKREDT1T2T3CONTROLCORDPOWERCORDELECTRODEPROBE TEST RESISTOR ONHAZARDOUS LOCATION ONLYSTATORGROUNDSCREWHEAT SENSORON STATOR200 VOLT – THREE PHASEP1P2GROUNDSCREWCONTROLCORDPOWERCORD230 VOLT – THREE PHASEBLACKYELLOWREDYELLOWBLACKREDGREENGREENP1P2REDREDHEAT SENSORON STATORPROBE TEST RESISTOR ONHAZARDOUS LOCATION ONLYSTATORT3T9 T2TBT1T7T4T5 T6ELECTRODECONTROLCORDPOWERCORDBLACKYELLOWREDYELLOWBLACKREDGREEN GREENGROUNDSCREWREDREDP2P1HEAT SENSORON STATORELECTRODEPROBE TEST RESISTOR ONHAZARDOUS LOCATION ONLYSTATORT1T2T3T4T7T5TBT6T9460 VOLT – THREE PHASEMotor Electrical DataHP Speed Volts Phase Freq. Max. Amps Locked Rotor Amps. KVA CodeLine Resistance2 1750 460 3 60 4 18.8 J 4.6Fairbanks Nijhuis™12/26/12FBM20 / FBMX20 Submersible Basin MixerInstruction and Repair Manual5CAUTION:Make sure that the ground wire is securely connected and that the unit is properly grounded in accordance with local codes.MIXER OPERATIONS:WARNING:Severe injury may result from accidental contact with moving propeller. Keep clothing, hands and feet away from propeller any time power is connected to the unit.STARTING THE MIXER:To start the mixer, perform the following steps in order: 1. If mixer is three phase, the rotation of the propeller must first be checked. Lift mixer from sump, lay it down, and quickly turn on and then off. The propeller should turn counterclockwise when viewed from the suction. If rotation is wrong, turn off main breaker and interchange any two line leads to motor to correct rotation. If mixer is single phase, no rotation check is necessary. 2. After installing mixer in basin in desired location, run water into basin until mixer is covered. 3. Turn mixer on and observe mixing action at the surface of the water. If required, adjust position of mixer mounting brackets until desired mixing action is achieved in the basin. 4. If problems occur, check the power source. Make sure a separate supply line is available. Verify the voltage supply.MIXER MAINTENANCE:DISASSEMBLY, INSPECTION, REASSEMBLY:Hazardous locations service:These mixers are to be used for handling sewage, wastewater and storm water only. DO NOT use in other hazardous locations. These motors must be repaired and serviced only at Fairbanks Nijhuis Authorized Service Centers or at the factory. Any unauthorized field repair voids the warranty, the hazardous locations rating, and Factory Mutual approval. 1. Turn off circuit break er.CAUTION:Never work on mixer with power on. Make sure that the ground wire is securely connected and that the unit is properly grounded in accordance with local codes. 2. Remove mixer from sump.Replacing seals: 1. Drain the oil in the seal cham ber by removing the drain plug on the side of the unit. If it con tains water, the lower seal has failed and should be replaced. The mo tor hous ing should be drained and the upper seal replaced if the lower seal has failed, since foreign material in the seal chamber may have dam aged the upper seal. 2. Remove the propeller after first removing center set screw at the end of the motor shaft. 3. Using a pair of snap ring pliers, remove the snap ring that secures the lower seal. Remove the lower seal rotating elements by sliding the spring off the shaft. Then, using two screwdrivers, slide the carbon assembly off by prying on the retaining ring. 4. Loosen and remove the cap screws that hold on the seal housing, then re move the seal housing. Using a socket that will fit onto the back of the seal, tap the sta tion ary seal assembly out of the seal housing. 5. Using a pair of snap ring pliers, remove the snap ring that secures the up per seal. Remove the spring retainer and spring from the shaft and, using the same method as used for the lower seal, remove the carbon seal assembly. 6. With a pair of screwdrivers, pry up on the seal/bearing plate. Remove the seal/bearing plate until you have access to the seal sensor wire, then carefully pull the seal sensor wire off the seal probe which will allow the complete removal of the seal/bearing plate.Fairbanks Nijhuis™ 12/26/12FBM20 / FBMX20 Submersible Basin MixerInstruction and Repair Manual6 7. Take a socket and tap out the stationary portion of the seal from the seal/bearing plate in the same manner as used for the lower stationary seal. 8. After checking both of the O-rings, replace the seal bearing plate in the motor housing, making sure that the seal sensor wire has been reattached to the seal probe. Use O-ring lube to prevent cutting in assembly. 9. Take the sta tion ary portion of the new seal and lube the rubber material with a good quality dielectric oil. Press the stationary portion of the new seal into the seal/bearing plate.CAUTION:Do not reuse old seal parts. Replace all parts with new. Mixing old and new parts could cause im me di ate seal failure. 10. Using a good quality dielectric oil, lube the rubber material on the carbon seal assembly and press it on the shaft. Place the spring and the seal retainer on the shaft as removed. Replace the snap ring. 11. Carefully place the seal housing onto the seal bearing plate, re place the cap screws, and tighten evenly. 12. Using a pressure gauge with a fill stem, pres sur ize the motor housing to no more than 7 psi with dried air and check for leaks. If after several minutes the gauge reads the same, the seal is good and you can con tin ue with assembly.NOTE: It is normal to observe some air bubbles in the seal area initially as the seal seats. If the bubbles do not stop within a few seconds, the seal is either not properly installed or is damaged. 13. Following the same pro ce dure outlined in steps 9 through 12, install the low er seal assembly. Re place the impeller using a re mov able locking adhesive. 14. Reassemble the propeller set screw onto mixer. 15. Refill all cham bers with a good quality di elec tric oil. Fill the motor housing so that the tops of the motor windings have been covered (2500 ml), but leave an air gap to allow for ex pan sion of the oil. Fill the seal chamber with 700 ml of oil so that an air gap also exists.Replacing motor stator: 1. If the replacement of the stator is necessary, first follow the disassembly steps outlined in the previous sections of the manual. 2. Remove the shaft rotor assembly from the motor hous ing, making note that a wave washer is used on the top of the upper bearing. 3. Place motor housing vertically on the bench and remove the cord grip. Care ful ly remove the power cord from the unit, making sure that the wires are not dam aged. Clip the power cable leads, taking note of the wire connections, and then re move the power cable. 4. Turn the motor hous ing over and remove the sta tor bolts from the stator, then remove the stator from the motor housing. 5. Place new stator into the motor housing while pulling the new leads through the power cord opening in the motor housing. Replace the stator bolts and tighten. Replace the seal sensor wire along the side of the sta tor. 6. Attach the power cord to the stator leads and the sensor leads using in su lat ed butt connector. Once attached, carefully tuck the wires into the motor housing, making sure they will not come in contact with the rotor. Press the power cord molded end into chamber in the motor housing. 7. Apply a sealant to the threads on the body of the cord grip that will enter the motor housing, then slide onto the power cord and tighten snugly. DO NOT OVERTIGHTEN. Attach the cord grip nut onto the cord grip and snug. 8. Examine the bearings on the shaft/rotor assembly. If they feel rough when rotated, re place. When reinstalling new bearings, press only on the inner ring of the bearing or damage may occur. 9. Replace the wave wash er into the upper bear ing pocket in the motor hous ing, then reinstall the rotor and shaft assembly. 10. Follow the previously outlined steps to reassemble the mixer from this point. 11. Always run mixer for a few seconds after assembly work to be sure all parts run smoothly before replacing it in the sump. Check again for correct rotation. Mixer should rotate counterclockwise when viewed from the propeller end.NOTE: When applying pow er, be sure the mixer is restrained from turning by holding the unit at the motor hous ing, or by clamping it in a holding fixture.Fairbanks Nijhuis™12/26/12FBM20 / FBMX20 Submersible Basin MixerInstruction and Repair Manual7WARNING:Severe injury may result from accidental contact with moving propeller. Keep clothing, hands and feet away from propeller any time power is connected to the mixer.Below is a list of troubles and their probable causes:Insufficient mixing 1. Mixer orientation needs adjusted 2. Wrong rotation 3. Speed too lowMixer overloads motor 1. Wrong rotation 2. Specific gravity or vis cos i ty of liquid too high 3. Speed too high 4. Mixer clogged 5. Defective bearingsMixer is noisy 1. Defective bearings 2. No axial clearance be tween propeller and seal housingIf the cause of the trouble cannot be determined and cor rect ed as outlined above, con tact your nearest factory rep re sen ta tive.Fairbanks Nijhuis™ 12/26/12FBM20 / FBMX20 Submersible Basin MixerInstruction and Repair Manual8SECTION A-AD5A21 D4 A14 A31 A11 A19 A28A13 B1 A29 A18 A17 1A4B2A30A15A32D7D2A11A20D6B3A12 A5A6D8D1A16A7A7 A8A28 A13BA24D3AABA1A25SECTION B-BA9A2 A3FBM / FBMX20Fairbanks Nijhuis™12/26/12FBM20 / FBMX20 Submersible Basin MixerInstruction and Repair Manual9FBM20 PARTS LIST For use with Regal Beloit MotorsItem # Description Part # Qty.1 CORD CAP 22407C607 1A1 SCREW – DRIVE #6 45800011 8A2 SCREW – SET 5/16-18 05013A027 2A3 PLUG – PIPE 1/4 05022A092 2A4 SCREW – MACHINE 10-24 x 3/8 05434A043 1A5 O-RING 05876A122 1A6 O-RING 05876A123 1A7 O-RING 05876A125 2A8 WASHER – LOCK 06107A015 1A9 SCREW – MACHINE 5/16-18 x 1 07597A017 2A10 TUBE – PLASTIC 10649A102 2A11 RING – RETAINING 12558A006 2A12 CONNECTOR – BUTT 22-16 12672A002 2A13 SCREW – HHC 5/16-18 x 1-1/4 19100A012 6A14 SCREW – CAP 5/16 x 7/8 19100A033 2A15 SCREW – CAP 5/16-18 x 1-1/2 001010101 2A16 WASHER – SPRING 19331A005 2A17 CAP – UPPER BEARING 21570B100 1A18 HOUSING – MOTOR 21571D100 1A19 HOUSING – UPPER SEAL 21574D100 1A20 PLUG – SPECIAL 1/2 HEx 21577A000 1A21 HOUSING – LOWER SEAL 21578C100 1A22 GREASE – LUBRICANT 22386A000 1A23 FERRULE – RUBBER .312 O.D. x .265 I.D. 22579A000 1A24 BRACKET – MIxER 526033065 1A25 NAMEPLATE 27674A500 1A26 OIL – TRANSFORMER 24709110000 0.5A27 PAINT 17005A028 1A28 SEAL – 7/8" 21576A010 2A29 BEARING – BALL 08565A03 1A30 BEARING – BALL 08565A018 1A31 ELECTRODE 22578A004A 1A32 SCREW – HHC 5/16-18 UNC x 1-3/4 001010111 2FAIRBANKS NIJHUIS RESERVES THE RIGHT TO SUBSTITUTE MATERIALS WITHOUT NOTICE.FBM / FBMX20 Motor Speci?c Parts ListItem # Description 1750 RPM 1150 RPMB1 ROTOR/SHAFT 152260111 152270111B2 STATOR 152260031 152270031B3 CONNECTOR 12672A001 (3) 12672A001 (3)Fairbanks Nijhuis™ 12/26/12FBM20 / FBMX20 Submersible Basin MixerInstruction and Repair Manual10FBMX20 PARTS LIST For use with Regal Beloit MotorsItem # Description Part # Qty.1 CORD CAP 22407C607 1A1 SCREW – DRIVE #6 45800011 8A2 SCREW – SET 5/16-18 05013A027 2A3 PLUG – PIPE 1/4 05022A092 2A4 SCREW – MACHINE 10-24 x 3/8 05434A043 1A5 O-RING 05876A122 1A6 O-RING 05876A123 1A7 O-RING 05876A125 2A8 WASHER – LOCK 06107A015 1A9 SCREW – MACHINE 5/16-18 x 1 07597A017 2A10 TUBE – PLASTIC 10649A102 2A11 RING – RETAINING 12558A006 1A12 CONNECTOR – BUTT 22-16 12672A002 2A13 SCREW – HHC 5/16-18 x 1-1/4 19100A012 8A14 SCREW – CAP 5/16 x 7/8 19100A033 8A15 SCREW – CAP 3/8-16 x 1-1/4 19101A017 2A16 WASHER – SPRING 19331A005 2A17 CAP – UPPER BEARING 21570B100x 1A18 HOUSING – MOTOR 21571D100x 1A19 HOUSING – UPPER SEAL 21574D100x 1A20 PLUG – SPECIAL 1/2 HEx 21577A000 1A21 HOUSING – LOWER SEAL 21578C100x 1A22 GREASE – LUBRICANT 22386A000 1A23 FERRULE – RUBBER .312 O.D. x .265 I.D. 22579A000 1A24 BRACKET – MIxER 526033065 1A25 NAMEPLATE 24332A501 1A26 OIL – TRANSFORMER 24709110000 0.5A27 PAINT 17005A028 1A28 SEAL – 7/8" 21576A010 2A29 BEARING – BALL 08565A013 1A30 BEARING – BALL 08565A018 1A31 ELECTRODE – WITH RESISTOR 22578A003 1A32 SCREW – HHC 5/16-18 UNC x 1-3/4 001010111 2FBM / FBMX20 Wet End Parts ListItem # Description Qty.D1 SCREW – CAP 5/16-18 001780041D2 WASHER – PROPELLER 005190001D3 KEY 3/16 SQ. x .69 101020011D4 HOUSING – LIP SEAL 134894002D5 LIP SEAL 152220001D6 PROPELLER 152120002D7 RING – PROPELLER 27755A000D8 SPACER – PROPELLER 27799A000THIS PAGE INTENTIONALLY LEFT BLANKTHIS PAGE INTENTIONALLY LEFT BLANK