ITT Industries FLYGT 4610 Instruction manual

1
4610, 4620 edition 03
Workshop manual
4610, 4620
893542/03

24610, 4620 edition 03
How to use the workshop manual ........... 3
Safety precautions ................................. 3
Data plate interpretation
General data plate .................................. 4
Approval plate ......................................... 5
Technical data
Winding resistances ............................. 6
Lubricants ............................................. 6
Checking of seal tightness .................... 6
Monitoring equipment ........................... 6
Specially approved mixer (Ex)
General ................................................... 7
Workshop repair...................................... 7
Guidelines for repair ............................... 7
Measurement for widths and gaps .......... 8
CONTENTS
Standard versions
4610.410
4620.410
Dismantling
Before starting......................................... 9
Tools ....................................................... 9
Oil draining ........................................... 10
Propeller ............................................... 10
Plug-in seal ........................................... 11
Cable disconnection ............................. 13
Bearing casing, bearings ...................... 15
Assembling
Bearing casing, bearings ...................... 16
Plug-in seal ........................................... 18
Cable connection (wire diagrams) ........ 20
Propeller ............................................... 23
Oil filling ................................................ 23
Notes ..................................................... 24
Exploded view
Accessories .......................................... 25
Mixer ..................................................... 26
PRODUCTS INCLUDED
Specially approved Versiones (Ex)
4610.490 EEx d llB T4
4620.490
4610.490 FM: Class l Div.1 Grp. C and D
4620.490 Class ll Div 1 Grp. E, F and G
Class lll Div. 1

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4610, 4620 edition 03
HOW TO USE THE WORKSHOP MANUAL
We would also like to point out that the practical work
involved in compiling this manual has been performed
under extremely favourable conditions. We have
dismantled and assembled a brand new product.
A product which has been in use for a longer period
of time has acquired a “patina” and other working
methods besides those recommended here will
sometimes have to be used.
If the product is specially approved, please read the
chapter “Specially approved mixer (Ex)”.
Flygt renounces all responsibility for work done by
untrained, unauthorized personnel.
This workshop manual describes how to dismantle
and assemble products 4610 and 4620 in connection
with repair and reconditioning work.
The operative part consists of step-by-step instruc-
tions together with illustrations for the different work
operations.
In the end you will find exploded views.
Details are also provided of the special tools which do
not only facilitate repair work but which are sometimes
necessary in order to carry out a particular operation.
Before starting work on the machine,
make sure that the machine is
disconnected from the power supply
and cannot be energized.
Make sure that the machine can’t roll
or fall over and injure people or
damage property.
Make sure that the lifting equipment
can handle the weight you want to
lift and that it is in good condition.
Keep out from suspended loads.
SAFETY PRECAUTIONS
Cut hazard
Worn parts may have sharp edges.
In order to minimize the risk of accident in connection
with service work, the following rules should be
followed.
- Never work alone. Use a lifting harness (part No.
84 33 02), a safety line (part No. 84 33 03) and a
respirator (part No. 84 33 01), as required. Do not
ignore the risk of drowning!
- Make sure that there is sufficient oxygen and that
there are no poisonous gases present.
- Check the explosion risk before welding or using
electric hand tools.
- Do not ignore health hazards. Observe strict clean-
liness.
- Bear in mind the risk of electrical accidents.
- Make sure that the lifting equipment and tools are
in good condition.
- Provide a suitable barrier around the work area, for
example a guard rail.
- Make sure that you have a clear path of retreat!
- Use a safety helmet, safety goggles and protective
shoes/gloves.
- All personnel who work with sewage systems
should be vaccinated against diseases that can
occur.
- A first-aid kit must be handy.
Follow all other health and safety rules and local
codes and practices.

44610, 4620 edition 03
DATA PLATE INTERPRETATION
General data plate
M
LN
V
U
T
RS
Q
P
O
I
JK
H
G
F
E
D
BC
X
A
A Serial number
B Product code + Number
C Curve code / Propeller code
D Country of origin
E Product number
F Additional information
G Phase; Type of current; Frequency
H Rated voltage
I Thermal protection
J Thermal class
K Rated shaft power
L International standard
M Degree of protection
N Rated current
O Rated speed
P Max. submergence
Q Direction of rotation: L=left, R=right
R Duty class
S Duty factor
T Product weight
U Locked rotor code letter
V Power factor
X Max. ambient temperature
Connection plate
Monitoring equipment
Blå/Blue Vit/White Vit/White
Blå/Blue Blå/Blue
alt Grå/Grey
alt Grå/Grey
Blå/Blue
FLS
Max 12 V
550 22 00
+T1
-T2
FLS

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4610, 4620 edition 03
Approval plates
Always together with the general data plate.
A Approval
B Approval authority + Approval Number
C Approval for Class I,
D Approved drive unit
E Stall time
F Starting current/Rated current
G Duty class
H Duty factor
I Input power
J Rated speed
K Controller
L Additional information
M Max. ambient temperature
N Serial Number
O ATEX marking
D
A
N
K
L
M
CB
F
E
GIJ
H
O
DATAPLATE INTERPRETATION
EN: European Norm,
ATEX Directive
EN 50 014, EN 50 018, EN 1127-1,
ll 2 G EEx dll T4
FM: Factory Mutual,
Class l Div. I Grp C and D
Class ll and III Div. I Grp E, F and G

64610, 4620 edition 03
TECHNICAL DATA
Lubricants
Part No Denomination
90 17 52 Oil (Mobil Whiterex 309)
90 18 00 Oil (Castrol iloform BWN 205)
Checking of seal tightness
The seal tightness can be checked by following procedure:
1. Make sure that there is no oil in the oil housing.
2. Apply a pressure in the oil housing (use the oil filling
hole).
- Applied pressure should be about 0.5 bar and
never above 1 bar as seal rings then might be
pushed out of position or seal may open.
- An accurate pressure gauge with high resolution
is needed to keep test time at a reasonable level.
3. Maximum allowed pressure drop over a certain
period of time is calculated as:
Po= pressure in test object [bar]
t = test time [min]
V = the volume of the test object (lit)
For weight, amperages, voltages, power ratings and
speed, please refer to the data plate of the machine.
50 Hz 60 Hz
Stator No Resistance Ohm/Phase
640 67 01 12.6 9
02 15.4 7.3
03 19.7 19
04 42.5 –
05 3.15 –
06 – 11
07 – 21
64068 01 6.91 6.91
02 8.62 –
03 10.7 10.7
04 21.2 –
05 1.72 –
06 – 4.73
07 – 1.29
64072 01 4.581) –
7.872) –
02 3.371) –
6.022) –
03 1.151) –
1.972) –
04 – 3.061)
– 5.202)
05 – 2.301)
– 4.002)
06 – 0.7641)
– 1.302)
1) Main phase 2) Auxiliaru phase
4610
3 Phase
4620
3 Phase
4620
1 Phase
Winding resistances at 20°C (68°F)
Monitoring equipment
Three thermal contacts are incorporated in the stator
and are normally closed. The thermal contacts can be
connected to:
- maximum of 250 volts
- breaking of 5 amps. current at maximum.
- rated 1.6, cosϕ= 0.6
- rated 2.5, cosϕ= 1
Connect the thermal contacts to the starter. See
connection plate, page 4 (or on connection house).
∆∆
∆∆
∆Pmax = 0.017 * Po* t/V [bar]
∆∆
∆∆
∆Pmax = pressure drop in test object [bar]
4. Location of any leak can be determined with soap
water.

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4610, 4620 edition 03
This chapter describes the specially approved mixer
versions 4610.490 and 4620.490. For identification,
see the mixer data plate and approval plate.
Specially approved mixers may
only be repaired and adjusted by
Flygt workshop and/or workshop
personnel authorized by Flygt.
General
In a specially approved product (explosion proof) the
gaps between different parts, for example the bearing
holder and the stator casing unit, shall prevent any
sparks from the interior of the machine from getting
out and igniting surrounding gases.
All joint widths and gaps shall be measured with
accurate and calibrated instruments. All joint surfaces
shall be inspected. No scratches, tool marks or the
like are permissible.
Failure to meet the above requirements may render
the special approval invalid. Note that the work
requires experienced and specially trained personnel.
To ensure that the product complies with the regula-
tions
and approval of the authorities, use only genuine
Flygt spare parts when carrying out repair work.
Always check the dimensions of vital parts before
assembly, see picture.
The assembled machine shall always be insulation-
tested
and test-run before delivery.
Workshop repair
The product must be thoroughly examined and a report
must be prepared on all findings. Any measurements,
dimensional checks, test regardings, details of mate-
rials,
parts of windings which are found require attention
should be carefully noted.
If the products have been modified and does not
comply with original approval, the owner must be
informed and further information on the application
must be requested.
If there are any doubts during the repair as to the
results of measurements, tests, the continued integrity
of parts or possible reclamation of damage parts,
reference must be made to your local Ex Coordinator.
Guidelines for repair
Dismantling
When dismantling Ex approved products, care must
be taken as damage to flameproof faces can easily
occur. For instance, if difficulties are found in separat-
ing
spigoted joints, draw studs should be used wher-ever
possible rather than trying to wedge the compo-nents
apart, as not only will damage occur at the point
of wedging, but the wedges are liable to be driven
through and damage the flamepath surface of the
spigot.
Similarly, care should be exercised when removing the
main bearing assembly and bearing holder to ensure
that damage does not occur on the parts that consti-
tute the flamepath.
Unless obviously damaged through either mechanical
injury or dry or wet burn out, the stator winding should
not be removed until preliminary testing has been done
to determine the condition of the stator winding and
monitoring devices, i.e. overtemperature thermal
switches.
The users instruction should be consulted to verify
whether the machine has been returned for repair
because of electrical problems, such as operation of
overload, short circuit or tripping out on an earth trip
leakage device.
Once the machine has been completely dismantled,
detailed examination of all parts should be made and
a concise record kept of all findings.
Assembling
Before assembling an Ex approved product, measure
the gaps and the joint widths. Inspect the joint surfaces
and smear them with grease to prevent corrosion.
If a part does not meet the requirements on dimen-
sional
accuracy or surface finish, it must be discarded
and a new specially approved part ordered. The new
part must also be inspected.
Observe caution during assembly to prevent damage
to the joint surfaces.
Flamepaths
Which parts require special examination can be
ascertained by refering to the Spare parts list and
dimensional checks.
The flamepaths should be examined for any corrosive
pitting or damage which may have occured.
All castings should be examined for blow holes or
hairline cracks. If there is evidence that there has
been an internal explosion of gases, this may be
confirmed by the user and will probably be evident by
smoke and debris tracking across the flamepaths.
SPECIALLYAPPROVED MIXER

84610, 4620 edition 03
SPECIALLYAPPROVED MIXER
Also violent damage will possibly have occurred to the
stator windings, stator leads and terminal boards or
bushings. In such cases, consideration should be
given to the renewal of all parts forming the flameproof
enclosure.
Using the dimensional check information for the parti-
cular
product under repair, the length of all flamepaths can
be measured using a vernier type gauge (the type
incorporating a depth gauge is particularly suitable for
this purpose).
When measuring flamepaths on spigoted parts, care
should be taken to measure only from the outer edge
of the flamepath to the outer edge of the “O” ring
groove. It would be unusual for these measurements
to be wrong as any corrosive or mechanical damage
affecting the length of the flamepath would be evident
by visual inspection.
The flameproof gap is ascertained by measuring the
outside diamater (OD) of the spigoted or male part
and the inside diameter (ID) of the female part of the
casting into which it fits. Measurements should be
taken at several points on the circumference and the
smaller (in case of OD) and the larger (in case of ID)
should be used to calculate the diametral clearance.
Micrometers should be used for taking measurements.
The calculation is simply to subtract the OD of male
part from the ID of the female part into which it fits.
Care and experience is required when taking any of
these measurements, as the tolerances are very fine.
For measuring the inside circumference of the stator
core or the outside diameters of rotors, special mea-
suring tools are required. Shaft outside diameter and
inside diameters of bearing casing etc. can be mea-
sured using micrometers.
The flameproof gaps should be calculated, recorded
and checked against the dimensional check table for
the product under repair.
Stator and rotor
Prior to examining the stator casing, preliminary
electrical testing of the stator winding should be
undertaken. This requires an insulation test between
windings and earth and between windings, for single
phase also between windings and auxiliaries.
The two monitoring cores should be short circuited
together during this test. A suitable test with a 1000
volt megger would be 20 MΩ.
The continuity of the thermal switches should be
measured to ensure their continued integrity. In the
rare case when thermistors and PT100 elements are
used, they can be tested using a digital type high
impedance instrument.
Joint Length of Diameter Gap of joint
joint mm mm mm
min max
I> 12,5 128 +0,15/-0 128 h7(0/-0,04) 0 0,19
II > 12,5 25,239 H6(+0,013/-0) 25 h5(+0/-0,009) 0,239 0,261
III min. 69,0 80 JS9(±0,037) 79,3 h9(+0/-0,074) 0,663 k = 0,05 0,811 m = 0,3
IV min. 69,35 125 -0,03/-0,1 125 k9(+0/-0) Shrinkfit
V> 12,5 124,3 +0/-0,2 124,4 ±0,05 Shrinkfit
VI >12,5 83 H8(+0,054/-0) 83 h8(+0/-0,054) 0 0,108
VI
V
IV
I
III
II

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4610, 4620 edition 03
DISMANTLING / ASSEMBLY
Dismantling
WARNING!
Before starting work on the machine,
make sure that the machine is
isolated from the power supply and
cannot be energized.This applies to
the control circuit as well.
1. Screwdrivers
2. Hexagon socket wrench
- 13 mm
3. Hexagon socket head cup wrench
-5mm
-6mm
4. Torque wrench (7 - 17 Nm/5.2 - 12.6 ft/lb)
hexagon socket head cup
-6mm
screwdriver socket bit
- 12 mm
5. Screw M12 x 60 turned down to ∅ 6 mm over a
length of 20 mm
6. Screw M8 x 50
7. Nippers for cutting closed end splices
8. Circlip pliers, SgA 20
1. Dismantle the jet ring (208, 210) and the guiding
claw unit (207).
a. Undo and remove the screws, washers and
nuts.
Tool: hexagon socket wrench (13 mm) ,
hex. socket head cup wrench (6 mm)
b. Remove the clamp.
c. Lift off the jet ring.
d. Dismantle the guiding claw unit in the same
way.
9. Puller (84 13 62)
10. Puller (84 20 48)
11. Bearing mounting set, SKF (84 15 45)
or
- tube Di= 12 mm, Dy=19 mm for the smaller
bearing
- tube Di= 42 mm, Dy=52 mm for the larger
bearing (outer ring)
- tube Di= 20 mm, Dy=30 mm for the larger
bearing (inner ring)
12. Club
13. Knife
14. Stripping tongs
15 Pliers for clamping closed end splice
16. Funnel
17. Oil tray
19. Screw vice
20. Drift, ∅ 24 mm
21. 2 stiff wires (l=400 mm) with a flatten bend end
22. Tube for shaft. Di=23 mm, Dy=30 mm
Before starting the work on the machine, make sure
that all tools are at hand (see list).
Make sure that O-rings and any other parts that are to
be replaced are set out.
Clean the outside of the mixer before.
In the dismantling/assembly instructions the position
numbers in parenthesis refers to the exploded views on
page 25 and 26.
Specially approved mixers may
only be repaired and adjusted by
Flygt workshop and/or workshop
personnel authorized by Flygt.
Tools
Before starting

10 4610, 4620 edition 03
2. Remove the propeller.
a. Remove the plastic plug (94).
Tool: screwdriver
b. Undo the central screw and washer.
Tool: hex. socket head cup wrench (6 mm)
c. Lift off the propeller together with screw and
washer.
3. Check for seal leakage.
a. Attach the mixer in a screw vice. Use the
lifting handle (131) as attachment.
b. Undo and remove the inspection screw (with
O-ring
Tool: screwdriver
d. Undo the mixer from the screw vice and turn
the mixer upside down over an oil tray.
If any liquid runs out , the seal is worn out and
has to be replaced.
4. Empty the oil (and check for water in oil).
a. Remove both oil screws (and O-rings).
b. Tap all oil in an oil tray. Turn the mixer back
and forth to make sure that all oil is tapped.
Tool: Oil tray
c. Check if there are any water in the oil. If there
are, the seal is worn out and has to be
replaced.
Oil screw (drainage)
Oil screw (filling)
Cut hazard
A worn propeller may
have sharp edges
Inspection screw

11
4610, 4620 edition 03
5. Dismantle the oil housing (63).
a Attach the mixer to the screw vice.
b. Undo and remove the screws (and seal
washers).
Tool: hex. socket head cup wrench (5 mm).
c. Fit M12 x 60 screws to the oil filling holes.
d. Press off the oil housing by tighten the screws
alternately.
Tool: screw M12 x 60
e. Remove the O-rings (24) and (27).
f. Wipe off any oil inside the oil housing.
repeat step 2 and 5.
6. Dismantle the plug-in seal (80).
a. Remove the retaining ring.
Tool: circlip pliers (SgA 20)
b. Dismantle the plug-in seal from the shaft.
7. Dismantle the bearing cover (64).
a. Remove the O-ring (24).
b. Undo and remove the screws. Discard the
washers.
Tool: hex. socket head cup wrench (5 mm)
c. Use the M12 x 60 screw to undo the bearing
cover.
Tool: screw M12 x 60

12 4610, 4620 edition 03
8.Remove the spring (55).
a. Knock gently on the bearing casing.
Tool: club
b. Remove the spring carefully with two screw
drivers.
Tool: screwdriver
9.Dismantle the entrance flange (121).
a. Turn the mixer in the screw vice (cable
entry facing upwards).
b. Undo and remove the screws (and seal
washers).
Tool: hex. socket head cup wrench (5 mm)
c. Dismantle the entrance flange.
d. Remove the clamp (112).
e. Move the cable entry parts by the cable.
10. Dismantle the entrance cover (124).
a. Undo and remove the screws (and seal
washers).
Tool: hex. socket head cup wrench (5 mm).
b. Move the entrance cover by the cable.

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4610, 4620 edition 03
11. Dismantle the connection housing (123).
a. Remove the O-ring (29) by the cable.
b. Undo and remove the screws.
Tool: hex. socket head cup wrench (5 mm).
c. Lift off and move the connection housing by
the cable.
12. Disconnect the cable.
a. Cut the closed end splice of each conductor
with a nippers.
Tool: nippers
13. Remove all parts from the cable.
Entrance flange O-ring
Entrance cover O-ring

14 4610, 4620 edition 03
14. Dismantle the shaft-rotor unit (60).
a. Fit the screw to the back end of the stator
housing unit (the bearing casing).
Tool: screw M8 x 50
b. Press out the shaft-rotor unit by tighten the
screw while holding the shaft-rotor unit with the
other hand.
c. Remove the screw.
d. Undo the stator housing unit from the screw
vice.
15. Remove O-ring (61.2) from the stator housing unit.
a. Put the stator housing unit on the work bench.
b. Remove the O-ring from the groove.
Tool: stiff wires
c. Turn the stator housing upside down to get the
O-ring out.
16. Remove the O-rings from bearing casing (62).
a. Fit the propeller screw (8) to the shaft end to
protect it from damage.
b. Remove the O-rings.
WiresO-ring

15
4610, 4620 edition 03
17. Dismantle the bearing casing (62) from the shaft-
rotor unit (60).
a. Fit the puller.
Tool: puller 841362
NOTE!
Only a puller with three claws must be
used. Otherwise the bearing casing may be
damaged.
b. Attach the shaft-rotor unit to the screw vice.
Use the puller as bracket.
c. Tighten the puller screw while holding shaft-
rotor unit with the other hand.
d. Remove the puller.
18. Dismantle the bearing (50) from the rotor-shaft.
a. Attach a tube to the screw vice.
Tool: tube for shaft
b. Place the shaft-rotor into the tube.
c. Fit the puller to the bearing.
Tool: puller 842048
d. Pull the bearing off.
19. Dismantle the bearing (51) from the bearing
casing.
a. Place the bearing casing on the work bench.
b. Knock the bearing off with a drift.
Tool: drift (D=24 mm)

16 4610, 4620 edition 03
Assembling
Before starting the work:
- Clean all parts throughly, particularly O-ring
grooves.
1. Assemble the bearing (51) and the bearing
casing (62).
a. Place the bearing casing on the work bench.
b. Fit the bearing in position with the bearing
designation upwards.
c. Knock on the outer bearing ring with a drift until
bearing is in place.
Tool: SKF B20-52 or
tube (D
i
=42 mm, D
y
=52 mm)
2. Fit the bearing casing to the shaft-rotor unit (60).
a. Place the shaft-rotor unit on the work bench.
b. Fit the bearing casing.
c. Tap the bearing in place.
Tool: SKF B20-52 or
tube (D
i
=20 mm, D
y
=30 mm)
d. Fit the O-rings to the bearing casing.
3. Fit the O-rings (28 and 29) to the bearing casing.
29
29
29
28

17
4610, 4620 edition 03
e. Check that the spring groove is visible. If not,
the bearing casing was not mounted in correct
position on the shaft. Repeat step 2 and 5.
6. Assemble the shaft-rotor unit and the stator
housing unit.
a. NOTE! Attach the stator housing unit to the
screw vice.
b. Place the shaft-rotor unit into the stator hous
ing and press.
c. Turn the shaft rotor in right position.
The “Down”mark on the bearing casing (64)
should point at the same angle as the “Down”
mark on the back bearing casing (62).
d. Knock gently on the shaft end with a club to
get the shaft-rotor unit in place.
Tool:club
4. Assemble the back bearing (50) to the shaft-rotor
unit.
a. Attach a tube to the screw vice.
Tool: Tube D
i
=24 mm
b. Place the front shaft end into the tube.
c. Fit a new bearing to the back shaft end.
d. Tap the bearing is in place.
Tool: SKF A12-37 or
tube D
i
=12 mm, D
y
=19 mm
5. Fit O-ring (61.2) to the stator housing unit.
a. Let the O-ring slide down in place by a screw
driver.
Tool: screwdriver
b. Use two screwdrivers to place the O-ring to
the O-ring seat.
Tool: screwdrivers

18 4610, 4620 edition 03
7. Fit the spring (55).
a. Fit the spring to the groove in the stator
housing. Using a screwdriver will facilitate the
mounting.
Tool: screwdriver
b. Pull the shaft-rotor unit against the spring.
8. Fit the bearing cover (64).
a. Fit the bearing cover.The "Down" mark on
the bearing cover should point at the
same angle as the "Down" mark on the
back bearing casing (62).
b. Fit new washers (19) to the screws.
c. Fit the screws and washers and tighten
alternately to 7-11 Nm/5.2-8.2 ft lb.
Tool: hex. socket head cup wrench (5
mm)
d. Check that the shaft rotates free.
9. Fit the plug- in seal.
a. Turn the seal unit so that the carrier lip fits into
the shaft groove. Press the seal in correct
position.
Spring
Stator housing
Shaft-rotor unit

19
4610, 4620 edition 03
10. Fit the retaining ring.
a. Make sure that the retaining ring has entered
the groove (check by knocking with a screw
driver on the ring).
Tool: circlip pliers, screwdriver
The retaining ring has one flat and
one crowned side. The crowned side
should face the seal.
NOTE!
11. Fit O-rings (27) and (24).
a. Place the O-ring (27) concentric on the plug-in
seal.
b. Fit O-ring (24) to the inspection hole.
12. Fit the oil housing (63).
a. Fit the O-ring (29) to the oil housing.
b. Turn the oil housing inright position and fit it.
The inspection holes in oil housing and bearing
cover should face each other.
c. Fit the screws (and seal washers) and tighten
alternaty to 7 Nm/5.2 ft lb .
Tool: hex. socket head cup wrench (5 mm)
29
27 24
29

20 4610, 4620 edition 03
13. Connect the cable to the mixer.
a. Thread following parts in order on to the cable:
entrance flange (121) with O-ring (26) , gasket
(113), washer (114), seal sleeve (111), washer
(114), entrance cover (124) with O-ring (29) ,
connection housing (123).
b. Strip the outer isolation over a length of 8 cm
(3.1”) and the leads.
Tool: knife, stripping tongs, pliers
For safety reasons, the earth lead should
be longer than the phase leads. If the
motor cable is jerked loose by mistake
the earth lead should be the last to come
loose from its terminal. This applies to
both ends of the cable.
NOTE!
111 114 113 26
123 29 114124 121113