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ITT Industries FLYGHT 4610 Maintenance manual

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Installation, care and maintenance
4610, 4620
893493/03
2
CONTENTS
This “Installation, Care and
Maintenance” applies to the following
versions of the 4600-series:
4610 4620
4610.410 4620.410
4610.490 4620.490
Notes for explosion approved ____ 3
Guarantee ____________________________ 3
Data plate interpretation ___________ 4
Product description ________________ 5
Applications _____________________________ 5
Motor data _______________________________ 5
Design __________________________________ 6
Materials _________________________________ 7
Weights __________________________________ 7
Transportation and storage_________ 8
Installation ____________________________ 8
Safety precautions _________________________ 8
Handling equipment ________________________ 9
Installation alternatives _____________________ 9
Page Page
Electrical connections _____________ 10
Operation ____________________________ 13
Before starting ___________________________ 13
During operation __________________________ 13
Care and maintenance _____________ 14
Safety precautions ________________________ 14
Service __________________________________ 14
Recommended inspections _________________ 15
Changing the oil __________________________ 17
Replacing the propeller ____________________ 17
Fault tracing (Troubleshooting) ___ 18
General Danger:
Non-observance given to safety
instructions in this manual, which
could cause danger to life have
been specifically highlighted with
this general danger symbol.
High Voltage:
The presence of a dangerous volt-
age is identified with this safety
symbol.
Non-observance to this warning
could damage the unit or affect its
function
WARNING!
Identification of safety and warning
symbols
3
Flygt guarantees that a spare parts stock will be kept
for 15 years after the manufacture of this product has
been discontinued.
The manufacturer reserves the right to alter perfor-
mance, specification or design without notice.
Official approval applies only providing:
—that the product is used under condition
described in the care and maintenance
instructions and in applications for which
it is intended;
—that the monitoring equipment incorporated
in the product is correctly connected;
—that all service and repair work is done by
a workshop authorized by Flygt;
—that genuine Flygt parts are used.
Flygt undertakes to remedy faults in products sold by
Flygt provided:
— that the fault is due to defects in design, materials
or workmanship;
— that the fault is reported to Flygt or Flygt’s repre-
sentative during the guarantee period;
— that the product is used only under conditions de-
scribed in the care and maintenance instructions
and in applications for which it is intended;
— that the monitoring equipment incorporated in the
product is correctly connected;
— that all service and repair work is done by a work-
shop authorized by Flygt;
— that genuine Flygt parts are used.
Hence, the guarantee does not cover faults caused by
deficient maintenance, improper installation, incorrect-
ly executed repair work or normal wear and tear.
Flygt assumes no liability for bodily injuries, material
damages or economic losses beyond what is stated
above.
GUARANTEE
The explosion proof version (Ex-approved) is de-
signed for use in explosive environments in accor-
dance with approvals stated on page 4.
Thermal contacts must always be
used on Ex-approved machine due
to approval conditions.
All work on the explosion-proof
motor section must be performed by
personnel authorized by Flygt.
Flygt disclaims all responsibility
for work done by untrained,
unauthorized personnel.
NOTES FOR EXPLOSION
APPROVED MACHINES
According to rules the Ex-approved
mixer must always work completely
submerged in the liquid.
4
DATA PLATE INTERPRETATION
APPROVAL PLATES
Always together with the general data plate.
EN: European Norm,
ATEX Directive
EN 50 014, EN 50 018, EN 1127-1,
ll 2 G EEx dll T4
GENERAL DATA PLATE A Serial number
B Product code + Number
C Curve 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
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
M
LN
V
U
T
RS
Q
P
O
I
JK
H
G
F
E
D
BC
X
A
FM: Factory Mutual,
Class l Div. I Grp C and D
Class ll and III Div. I Grp E, F and G
Temperature class T4
Max. ambient temperature 40°C (105°F)
5
PRODUCT DESCRIPTION
Motor data
Data for liquid max 40°C (105°F)
4610
Applications
The mixer is intended to be used in:
— waste water treatment, anaerobic or oxygen satu-
rated water, presence of rags etc.
— industrial processes, heavy environments with high
demands of operational security, food and chemical
industry.
— industrial sewage processes, some wearing, pres-
ence of rags and metallic salt.
— mineral slurries with high wearing characteristics,
presence of rags acceptable.
— fish farms and current creating in dams, oxygen
supply, demands of environmental approved
materials. Sweet or brackish water.
The mixer is designed for use in many different situa-
tions where high flow capacity in relation to power
consumption is required such as solids suspension
and blending application.
The mixing effect is dependent upon the density and
the viscosity of the liquid and on the volume/shape of
the tank.
More than one mixer is required for larger tanks.
For other applications, contact your nearest Flygt
representative for information.
60 Hz, 0.9 kW (1.2 hp),
3 phase, 4 pole, 1685**r/min
Voltage Rated Starting
current current
VAA
200Y 3,5 16
200Y 4,0 21
220D 3.6 19
230Y 3,6 20
380Y 2,1 11
400Y 2,0 11
460Y 1,7 9
480Y 1,7 9,5
575Y 1,4 7,3
600Y 1,4 7,6
**) 460 V
50 Hz, 0.75 kW,
3 phase, 4 pole, 1385* r/min
Voltage Rated Starting
current current
VAA
200Y 3,5 16
230D 3,0 14
380Y 1,8 7,7
400Y 1,7 8,1
415Y 1,7 8,4
440Y 1,6 7,3
500Y 1,4 6,5
690Y 1,0 4,4
*) 400 V
50 Hz, 1,5 kW,
3 phase, 4 pole, 1390* r/min
Voltage Rated Starting
current current
VAA
200Y 7,2 28
230D 6,3 24
380Y 3,7 13
400Y 3,6 14
415Y 3,7 15
440Y 3,3 13
500Y 2,9 11
690Y 2,1 8,2
*) 400 V
60 Hz, 1,7 kW, (2,3 hp)
3 phase, 4 pole, 1670** r/min
Voltage Rated Starting
current current
VAA
200Y 7,7 37
220D 7,1 34
230D 7,3 35
380Y 4,1 19
400Y 3,9 18
440Y 3,5 16
460Y 3,3 16
480Y 3,4 17
575Y 2,7 13
600Y 2,7 13
**) 460 V
4620
4620
50 Hz, 0,75 kW,
1 phase, 4 pole, 1435* r/min
Voltage Rated Starting
current current
VAA
115 9,8 46
200 5,7 29
230 4,9 23
60 Hz, 0,9 kW (1,2 hp),
1 phase, 4 pole, 1740**r/min
Voltage Rated Starting
current current
VAA
115 11 58
200 6,7 37
220 5,5 27
230 5,5 29
*) 200 V **) 200 V
Only Ex-approved machines may be
used in explosive or flammable
environments or for mixing flamma-
ble liquids.
General description
These care and maintenance instructions apply to
both the standard version and the explosion proof
version of the submersible Flygt mixers.
The explosion proof version (Ex-approved) is
designed for use in explosive environments in
accordance with the approvals, see page 4.
The pH of the liquid: 1—12.
Liquid temperature: max. 40°C (105°F).
Warm liquid version max. 90°C (195°F). This version
has model designation ending with -W.
Depth of immersion: max. 20 m (65 ft).
Note, Ex-approved machines are permitted for max
liquid temperature 40°C (105°F).
Design
1. Cable entry
The cable entry has a sleeve and a compressible
rubber bushing to seal off and to relieve the cable.
2. Junction box
The junction box is completely sealed off from the
surrounding liquid.
3. Monitoring equipment
The stator incorporates three thermal contacts con-
nected in series.
The thermal contacts open at 125°C (260°F).
The thermal contacts should be connected for liquid
temperatures up to 40°C (105°F).
NOTE! The thermal contacts must always be connect-
ed in Ex-approved mixer.
See also “Electrical connections” and separate in-
structions for starter equipment.
The mixer can be equipped with leakage detector,
FLS 30, for sensing water in the inspection compart-
ment.
4. Motor
Squirrel-cage 3-phase induction motor for 50 Hz or 60
Hz.
The motor is started by means of direct on-line start.
The motor can be run continuously or intermittently
with a maximum of 15 evenly spaced starts per hour.
The stator is insulated in accordance with class F
(155°C, 310°F). The motor is designed to supply its
rated output at ± 5 % variation of the rated voltage.
Without overheating the motor, ± 10 % variation of the
rated voltage can be accepted provided that the motor
does not run continuously at full load. The motor is
designed to operate with a voltage imbalance of up to
2 % between the phases.
5. Bearings
The shaft is carried in two prelubricated and enclosed
ball bearings.
The bearings are dimensioned for more than 100 000
(L 10 aa) hours of operation.
6. Shaft
The motor shaft is delivered with the rotor as an inte-
gral part.
The motor shaft is completely sealed and will not
come in contact with the liquid.
7. Inspection chamber
An inspection screw facilitates checking for leakage of
liquid into the space behind the plug-in seal.
8. Oil housing
The oil lubricates and cools the seals, and acts as an
additional barrier against penetrating liquid.
Pressure build-up within the seal housing is reduced
by means of a built-in air volume.
9. Shaft seals
The mixer has a plug-in seal, which combines an inner
and an outer seal into one, rigid unit.
10. Propeller
The propeller is two-bladed and the blades have a
large width and a thin profile.
Jet ring
The mixer can be operated with or without a jet ring.
The jet ring improves the efficiency.
NOTE. Operation without jet ring affects the
power consumption.
Jet ring with vortex protective shield
In order to avoid vortex, the machine can be equipped
with a jet ring with protective shield.
6
5
9
4
56
123
810
7
7
Materials
Denomination Material Flygt No EN ASTM
Propeller, Jet ring, Stainless 0344. 1.4432 316L
Support, Lifting steel 2343.02
device:
Propeller1) Stainless
steel
Hi-Chrome
Shaft: Stainless 0344. 1.4057 431
steel 2321.03
Seal housing, Vinylester 0544. — —
Entrance cover: SMC CR30 9585.70
O-rings, Nitrile 0516. — —
Cable entry, rubber (NBR) 2637.04
Seal and rubber 70°IRH (black)
sleeve:
O-rings, Gasket, Fluorinated- 0516. — —
Cable entry, rubber (FPM) 2677.32
Seal and rubber 70°IRH (green)
sleeve:
Shaft seals:
Inner seals Outer seals O-rings
WCCR/WCCR RSiC/RSiC FPM
AL2O3/WCCR WCCR/WCCR FPM
AL2O3/CSb AL2O3/WCCR NBR
Corrosion resistant cemented carbide (WCCR)
Aluminium oxid (AL2O3)
Silicon carbide (RSiC)
Carbon (CSb)
1) only 4620 3-phase
Weights
Weight of mixer without motor cable is:
Min. kg (lb)
4610 11,5 (24,2)
4620 12,8 (26,5)
Max*. kg (lb)
4610 15,5 (35,3)
4620 17,0 (37,5)
*Incl. Jetring, vortex protection shield and guide claw unit
8
TRANSPORTATION AND STORAGE
WARNING! Always lift the machine by the lifting
device, never by the motor cable.
For a longer periods of storage, the mixer must be
protected against moisture and heat. The propeller
should be rotated by hand occasionally to prevent the
seals from sticking together. If the mixer is stored for
more than 6 months, this rotating is mandatory.
After a long period of storage, the mixer should be
inspected before it is put into operation. Pay special
attention to the seals and the cable entry.
To reduce the risk of electric shock,
see chapter “Installation”and
“Electrical connections”.
The tank of a sewage treatment plant
must be vented in accordance with
local plumbing codes.
The machine is not to be installed in
locations classified as hazardous in
accordance with the national electric
code, ANSI7NFPA 70-1990.
CAUTION!
This machine is intended to run fully
submerged. Level sensing equip-
ment should be installed if there is a
possibility that the machine could be
operated at less than the “minimum
submergence depth”.
INSTALLATION
Safety precautions
In order to minimize the risk of accidents in connection
with the service and installation work, the following
rules should be followed:
1. 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!
2. Make sure that there is sufficient oxygen and that
there are no poisonous gases present.
3. Check the explosion risk before welding or using
electric hand tools.
4. Do not ignore health hazards. Observe strict clean-
liness.
5. Bear in mind the risk of electrical accidents.
6 Make sure that the lifting equipment is in good
condition.
7. Provide a suitable barrier around the work area, for
example a guard rail.
8. Make sure that you have a clear path of retreat!
9. Use a safety helmet, safety goggles and protective
shoes/gloves.
10. All personnel who work with sewage systems
should be vaccinated against diseases that can
occur.
11. A first-aid kit must be available.
Follow all other health and safety rules and local
codes and practices.
In order to avoid accidents, warning
signs for rotating propellers and
machines that start automatically
must be positioned visibly. The area
in the proximinity of the machines
should be fenced off.
When mixing near a lake (jetties,
beaches and ponds etc.) a safety
distance of at least 20 meters (65 ft)
between the person and the ma-
chine is necessary. The machine
must never be placed directly in a
swimming pool. If used in connec-
tion with swimming pools, special
safety regulations apply.
Make sure that the mixer can’t roll or
fall over and injure people or damage
property.
Ex version!
Installation of the explosion-proof
mixer must be performed by autho-
rized personnel.
For some installations, and at cer-
tain operating points on the perfor-
mance curve, the noise level 70 dB
or the noise level specified for the
actual machine can be exceeded.
9
± 20°
± 60°
± 90°
± 30°
45°-180°
Installation alternatives
Flygt supplies equipment for the below methods of
installation which permit mixing over the horizontal
and the vertical plane.
NOTE!
If the mixer is operated without a jet ring, there
must be a stop function on the guide bar
to avoid the propeller from being swung
into the wall during operation.
Don´t position the mixer when it is operating.
All welded joints must be pickled and polished
before they come into contact with the liquid.
Handling equipment
Lifting equipment will facilitate handling of the mixer.
Normally the mixer can easily be installed without any
special lifting equipment.
WARNING! Always lift the machine by the lifting
device, never by the motor cable.
Keep out from suspended loads.
Make sure that the machine can't roll
or fall over and injure people
or damage property.
Avoid installations where:
— there are obstacles in front of the mixer,
— the flow on the suction side of the mixer is obstruct-
ed due to the design of the tank,
— the propeller can suck down air - vortex,
— directly over bottom diffusers.
To avoid vortex use a vortex protective shield or place
the mixer deeper in the liquid.
This is an absolute requirement for continuously oper-
ating mixers.
The mixer can be mounted on fixed structures, pillars,
stands, gratings, an anchored raft etc.
When installing, keep in mind the reaction force of the
mixer, which can be up to, for: 4610 260 N
4620 420 N
Run the cables so that they do not have any sharp
bends and are not pinched.
NOTE! The end of the cable may not be submerged.
Leads must be above flood level, as water may pene-
trate through the cable into the junction box or the
motor.
Consult your nearest Flygt representative regarding:
— choice of peripheral equipment.
— other problems in connection with installation.
In all installations, make sure that
the motor cable cannot be drawn
into the propeller.
Treat the cable as fragile, beware
that no sharp bends occure during
installation procedures, especially at
the entrance flange.
The “Cantilever system”
The “Single guide bar system”
The “Bottom fixing bracket system”
10
ELECTRICAL CONNECTIONS
All electrical work must be carried out under the super-
vision of an authorized electrician.
Local codes and regulations must be observed.
Check that the voltage and frequency on the data
plate agree with your actual power supply.
The motor can´t be connected for different voltages.
If intermittent operation is prescribed (see data plate),
the mixer should be provided with control equipment
that provides such operation.
To avoid leakage into the mixer check:
— that the cable entry seal sleeve and washers con-
form to the outside diameter of the cable. See the
parts list.
— that the outer sheath on the cable is not damaged.
When refitting a cable which has been used before,
always cut off a short piece of the cable so that the
cable entry sleeve does not compress the cable at
the same point again.
Remember that the starting surge can be up to 3.5
times higher than the rated current. Make sure that the
fuses or circuit breakers are of the proper amperage.
The table (see “Product Description”) gives rated cur-
rent and starting current. Fuse amperage and cable
must be selected in accordance with local rules and
regulations.
The overload protection (motor protection breaker)
shall be set to the motor’s rated current as given on
the data plate. With a clockwise phase sequence
L1-L2-L3 (R-S-T), the propeller will rotate correctly,
i.e. clockwise as viewed from the motor side. Check
the phase sequence in the main (line) using a phase
sequence indicator.
Three thermal contacts are incorporated in the stator
and are normally closed. The thermal contacts can be
connected to maximum of 250 volts, breaking at 4
amps. current at maximum.
Connect the thermal contacts to the starter.
Motor cable
CAUTION!
If the machine is intended for use with a
Variable Frequency Drive (VFD), be careful in
choosing a motor cable. The VFD might require
a screened cable.
Please, read the manufacturer’s instruction for
the VFD.
If necessary, contact your ITT Flygt represen-
tative.
Available motor cable are SUBCAB®,SUBCAB®AWG
or a chemically resistant cable e.g. HCR.
Connect the motor cable to the terminal board as
illustrated in the figure “Direct on-line start”.
Connect the leads from the motor control circuit to T1
and T2.
Tighten the screws so that the cable entry unit forms
an effective seal.
Connect the motor cable to the starter equipment.
Check the direction of rotation, see “Before starting”.
If the direction of rotation is wrong, transpose two of
the phase leads, only for 3 phase.
For 1 phase mixers rotating in wrong direction, please
contact your nearest Flygt reprensative.
NOTE! With long cables, the voltage drop must
be taken into consideration, since the motor’s
rated voltage is the voltage measured at the
terminal board in the machine.
NOTE! 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.
Make sure that the mixer is
correctly earthed (grounded).
WARNING!
If persons are likely to come into
physical contact with the machine or
mixed media (liquid) the earthed
(grounded) socket must have an
additional earth-(ground-)fault
protection device (GFI) connected.
Ex version!
Electrical connection of the explo-
sion-proof mixer must be performed
by authorized personnel.
Before starting work on the machine,
make sure that the machine is
insulated from the power supply
and cannot be energized.
Flygt disclaims all responsibility for
work done by untrained, unautho-
rized personnel.
Thermal contacts must always be
used on Ex-approved machine due
to approval conditions.