Vendor Manual - Submersible Mixer Flygt Model 4650 Installation, Operation and Maintenance Manual

Installation, Operation and Maintenance

Mixer 4650

896508/6.0

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Installation, Operation and Maintenance

Mixer 4650

Overview

Table of Contents This publication contains the following topics:

Topic

Preface ...................................................................................................................................................... 5
Safety ........................................................................................................................................................ 6
Safety Regulations................................................................................................................................. 7
Safety Regulations for Ex-Approved Products.......................................................................................... 12
Legal Issues............................................................................................................................................... 14
Approvals .............................................................................................................................................. 15
Warranty ............................................................................................................................................... 16
Practical Information ................................................................................................................................... 17
Data Plate Interpretation......................................................................................................................... 18
Product Identity...................................................................................................................................... 21
Order parts ............................................................................................................................................ 23
Dimensional drawings ................................................................................................................................. 24
Lifting Davit ........................................................................................................................................... 25
Measurements for Brackets .................................................................................................................... 27
Mixer..................................................................................................................................................... 31
Install Lifting System ................................................................................................................................... 36
EU Declaration of Conformity.................................................................................................................. 37
Mount Lifting Davit ................................................................................................................................. 38
Mount Lifting Equipment......................................................................................................................... 42
Install Guide Bar System ............................................................................................................................. 45
Mount Single Guide Bar system .............................................................................................................. 46
Install the Mixer .......................................................................................................................................... 59
Install on a Single Guide Bar System ...................................................................................................... 60
Install on a Sloping Bottom ..................................................................................................................... 63
Install with Flange .................................................................................................................................. 65
Positioning the Mixer................................................................................................................................... 66
General description ................................................................................................................................ 67
Clearance.............................................................................................................................................. 68
Horizontal angle..................................................................................................................................... 69
Vertical angle......................................................................................................................................... 72
Electrical Installation ................................................................................................................................... 73
Power Supply ........................................................................................................................................ 74
Connection ............................................................................................................................................ 75
Cable Connection Diagrams ................................................................................................................... 76
Cable Connection to Controller ............................................................................................................... 79
Set up the Controller ................................................................................................................................... 80
First Start-Up.............................................................................................................................................. 81
Trouble Shooting ........................................................................................................................................ 82
If the Mixer Fails to Start......................................................................................................................... 83

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If the Mixer Starts but Motor Protection Trips ........................................................................................... 84

If the Mixer Starts, Stops and Starts in a Rapid Sequence ........................................................................ 85
Preventive Maintenance.............................................................................................................................. 86
Intermediate Service .............................................................................................................................. 87

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Preface
Purpose The purpose of this manual is to give the reader information about how to install the
product and its accessories.

Recipient The manual is principally intended for ITT Flygt

• service departments and
• customers.

Contact Please contact ITT Flygt documentation department if any information in this publication is
• missing
• difficult to find or
• irrelevant.

Reference More information about the product and how to handle it is available in the following
documents:
• Parts List
• Service and Maintenance

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Safety

Safety
Overview

Table of This chapter contains the following topics:

Contents
Topic
Safety Regulations ............................................................................................. 7
Environment.................................................................................................. 8
User Health and Safety.................................................................................. 10
Safety Regulations for Ex-Approved Products ...................................................... 12

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Safety, Safety Regulations

Safety Regulations

Introduction It is extremely important that you read, understand and follow the warnings and safety
regulations carefully before handling an ITT Flygt product. They are published to help
prevent
• personal accidents and health problems
• damages to the unit
• product malfunction

Reference For ex-approved products also see Safety Regulations for Ex-approved Products in this
book.

Symbols In the ITT Flygt documentation, admonitions are used together with the denomination.
The following items describes the safety levels of the admonition symbols in combination
with the denomination.

DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.

WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
injury

CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
injury

NOTE! Indicates a potential situation which, if not avoided, could result in undesirable results
or state. Indicates a practice not related to personal injury.

Presence of a dangerous voltage.

High Voltage

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Safety, Environment

Environment

NOTE! All dangers due to electricity must be avoided. Therefore, pay attention to the risks due
to electric shock or arc flash hazard. Also pay attention to the chemical and physical
characteristics of the gas and/or vapors present in hazardous areas.

Working areas Observe these regulations and warnings for the working areas.
• The pump/mixer station must always be kept tidy and in good order.
• If the product is used together with automatic level control, there is a risk of sudden
start.
• Warning signs for rotating propellers that start automatically must be positioned visibly.

Noise level The noise level of the products is lower than 70 dB, but in some installations and at certain
operating points on the performance curve the noise level of 70 dB may be exceeded.

Distance to When pumping or mixing near a lake or similar (e.g. jetties, beaches, ponds, fountains)
wet areas there must be a safety distance of at least 20 m (65 ft) between the person and the product
if the person is in contact with the pumped or mixed media.
The pump or mixer must never be placed directly into a swimming pool. If the product is
intended to be used in connection with swimming pools, special safety regulations apply.

Connections Make sure that the

• product is isolated from the power supply and cannot be energized before starting
work on it. This applies to the control circuit as well.
• thermal contacts are connected to a protection circuit intended for that purpose
according to the products approval.
• cable and cable entry have not been damaged during the transportation before the
unit is installed.
Intrinsically safe circuits are normally required for the automatic level control system by
level regulator if mounted in zone 0.

Earth Observe these regulations and warnings for earth connections.

connection • All electric equipment must be earthed.
This applies to pumps and mixers as well as to monitoring equipment.
• Make sure that the earth conductor is correctly connected by testing it.
Failure to heed this warning may cause fatal accident.
• If persons are likely to come into physical contact with the product or media, e.g.
on construction sites and farms, the earthed socket must have an additional earth
fault protection device connected to it.
• The earth conductor shall always be longer than the phase conductor. Rationale:
If the motor cable is jerked loose by mistake, the earth conductor shall be the last
conductor to be disconnected from its terminal. This applies to both ends of the cable.

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Safety, Environment

Recycling Laws and regulations regarding recycling must be followed. If there are no laws or
regulations, or the product is not accepted by an authorized recycling company, the product
or it’s parts can be returned to the nearest Flygt sales company or service workshop.

Disposal of All waste and emissions such as used coolant must be appropriately disposed of.
waste • Coolant spills must be cleaned up.
• Emissions to the environment must be reported.

Reference For electrical installation requirements, consult your local electric utility.

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Safety, User Health and Safety

User Health and Safety

NOTE! In order to minimize the risk of accidents, the following safety rules and local
regulations must be followed.

Precautions Observe the following safety precautions before working with the product:
before working • Make sure that the product cannot roll or fall over and injure people or damage
property.
• Use lifting harness, safety line and a respirator as required.
• Make sure that the lifting equipment is in good condition.
• Provide a suitable barrier around the work area, e.g a guard rail.
• Make sure you have a clear path of retreat.
• Make sure there are no poisonous gases within the work area.
• A first-aid kit must be close at hand.

Precautions Observe the following safety precautions when working with the product:
when working • Never work alone.
• Use safety helmet, safety goggles and protective shoes and gloves.
• Make sure that the product has been thoroughly cleaned and rinse the components in
water after dismantling.
• Stay clear of suspended loads.
• Always lift the product by its lifting device – never by the motor cable or the hose.
• Watch out for the starting jerk, which may be powerful.
• Check the explosion risk before welding or using electric hand tools.
Risks: Bear in mind the risk of:
• Drowning
• Electrical accidents
• Burn injuries

Health rules The product is designed for use in liquids which can be hazardous to health.
In order to prevent injury to the eyes and skin, observe the following points when working
on the product:
• All personnel who work with sewage systems must be vaccinated against diseases
to which they may be exposed.
• Observe strict cleanliness.
• Always wear goggles and protective gloves.
• Rinse the product thoroughly with clean water before starting work.

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Safety, User Health and Safety

Emergency Follow these steps if hazardous chemicals have splashed into your eyes.
instruction:
Step Action
Chemicals in
eyes 1 Hold your eyelids apart with your fingers and rinse your eyes immediately in
running water for 15 minutes.
2 Contact an eye specialist.

Emergency Follow these steps if hazardous chemicals have splashed on your body.
instruction: Step Action
Chemicals on
body 1 Remove contaminated clothes.
2 Wash your skin with soap and water.
3 If required, seek medical attention.

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Safety, Safety Regulations for Ex-Approved Products

Safety Regulations for Ex-Approved Products

Qualification All work on an Ex-approved product must be carried out by certified electricians and by
of personnel ITT Flygt authorized mechanics.

NOTE! Special rules apply to installation in explosive atmosphere. ITT Flygt disclaims all
responsibility for work done by untrained, unauthorized personnel.

Working areas

WARNING!
Only Ex-approved products may be used in an explosive or flammable environment!

Observe these regulations and warnings for the working areas.

• FM approved products must not be installed in locations classified as hazardous in
accordance with the national electric code, ANSI/NFPA 70–2005.
• ATEX approved equipment must be installed in conformity to international, national
and local standards (IEC/EN 60079–14).
• Do not open the product while energized or in an explosive gas atmosphere.
• The user must know about the risks due to the existence of electric current and the
chemical and physical characteristics of the gas and/or vapour present in hazardous
areas.
• Before start working on the product, make sure that the product and the control
panel are isolated from the power supply and cannot be energized. This applies to
the control circuit as well.

Minimum See the dimensional drawing of the product for minimum permitted water level according
water level to the ATEX approval.
The product must run fully submerged. Level sensing equipment should be installed if the
product could be operated at less than the minimum submergence depth, see dimensional
drawing.

Regulations Observe these regulations and warnings before working on the product or the equipment.
concerning the • ATEX approved equipment must be installed in conformity to international, national
equipment and local standards (IEC/EN 60079–14).
• The maintenance operation of ATEX approved equipment must be made in conformity
to the international, national and local standards (IEC/EN 60070–17).
• According to the ATEX directive, the Ex-product must never run dry or snore during
normal operation. Dry running during service and inspection is only permitted outside
the Ex area.
• Thermal contacts must be connected to a protection circuit according to the approval
of the product.
• The product may be used only in accordance with the approved motor data stated
on the data plates.
• Intrinsically safe circuits are normally required for the automatic level control system
by level regulator if mounted in zone 0.

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Safety, Safety Regulations for Ex-Approved Products

• Yield stress of fasteners according to ATEX approval and approval drawing.

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Legal Issues

Legal Issues
Overview
NOTE! The purpose of this chapter is to give the reader an overview of legal issues such as
standards, approvals and warranty of a product in general. For individual product
approval information, see approval plate on the product or Declaration of Conformity.

Table of This chapter contains the following topics:

Contents
Topic
Approvals .......................................................................................................... 15
Warranty............................................................................................................ 16

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Legal Issues, Approvals

Approvals

Standard All products are approved according to CSA standards in Canada and UL standards in
design USA.
The drive unit degree of protection follows IP68, see dataplate for max. submersion,
according to standard IEC 60529.

All electrical ratings and performance of the motors comply with IEC 60034-1.

Explosion- All explosion-proof products for use in explosive environments are designed in accordance
proof design with one or more of the following approvals:
• EN, ATEX Directive 94/9/EC, or/and
• FM According to NEC
Class 1 Div 1 Groups “C” and “D”
Class 2 Div 1 Groups “E”, “F”, and “G”
Class 3 Div 1 Hazardous Locations

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Legal Issues, Warranty

Warranty

Qualification All work on the product, standard or explosion-proof, must be carried out by certified
of personnel electricians and ITT Flygt-authorized mechanics.
ITT Flygt disclaims all responsibility for work done by untrained, unauthorized personnel.

Modification Modifications or changes to the product/installation should only be carried out after
and spare consulting with ITT Flygt.
parts Original spare parts and accessories authorized by ITT Flygt are essential for compliance.
The use of other parts
• can invalidate any claims for warranty or compensation or
• jeopardize explosion proof approvals.

NOTE! Only ex-approved spare parts and accessories authorized by ITT Flygt are allowed in
ex-approved products.

Warranty claim For warranty claim, contact your ITT Flygt representative.

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Practical Information
Overview

Table of This chapter contains the following topics:

Contents
Topic
Data Plate Interpretation ..................................................................................... 18
Data Plate..................................................................................................... 18
Approval Plate – FM approved version............................................................ 19
Approval Plate – EN approved version............................................................ 19
Product Identity.................................................................................................. 21
Order parts ........................................................................................................ 23

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Practical Information, Data Plate Interpretation

Data Plate Interpretation

Introduction The ITT Flygt product is always provided with data plates:
• The general data plate is used on all products.
• The approval plate is added to all explosion proof products.

Data Plate
The product may only be operated within the parameters stated on the data plate.

Illustration This is an illustration of a general data plate.

A

B C

E Y
F Z
X
G
V
H
U
I

J K L M N O P Q R S T

Field This table shows the fields on the general data plate, and which information each field
description contains.
Field Description Field Description
A Serial number N Rated current
B Product code O Rated speed
C Curve code + number P Maximal submersion
D Country of origin Q Direction of rotation:
• L = Left
• R = Right
E Product number R Duty class
F Additional information S Duty factor
G Phase; type of current, T Product weight
frequency
H Rated voltage U Locked rotor code letter

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Practical Information, Approval Plate – FM approved version

Field Description Field Description

I Thermal protection V Power factor
J Thermal class X Maximal ambient temperature
K Rated shaft power Y Notified body (only for
EN-approved Ex-products)
L International standard Z Read Installation Manual
M Degree of protection

Approval Plate – FM approved version

Illustration This is an illustration of an approval plate for the FM approved product version.

Approval Plate – EN approved version

Illustration This is an illustration of an approval plate for the EN approved product version.

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Practical Information, Approval Plate – EN approved version

A B C

O
D N
M
L
E K

F G H I J

Field This table shows the fields on the approval plate.

description Field Description Field Description
A Approval I Input power
B Approval authority + Approval J Rated speed
Number
C Approval for Class 1 K Controller
D Approved drive unit L Additional information
E Stall time M Max. ambient temperature
F Starting current / Rated current N Serial number
G Duty class O ATEX marking
H Duty factor — —

Approval The approval for the European version according to ATEX Directive 94/9/EC is shown on
the Approval Plate with one of the following information:

IM2 EEx de I

IM2 EEx dI

II2G EEx de IIB T3

II2G EEx d IIB T3

II2G EEx d IIB T4

Cable entry: The approval for the cable entry has the following certificate number:
INERIS 02ATEX 9008 U

II 2 G or IM2 EEx dIIC or EEx dI

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Practical Information, Product Identity

Product Identity

Sales The products identity is built up of the Sales Code (four digit) and two letters indicating
denomination hydraulic end and type of installation.
This is an example of a sales denomination.

NP 3085

1 2 3
Table: This table explains what the letters and the numbers in the sales code stand for.

Code Position Gives information about the...

1 hydraulic part

2 installation mode

3 sales code

Product code In each range the product´s identity, Product Code, is made up of seven digits.
This is an example of a product code.

NP 3085.183

1 2
Table: This table explains what the product code is made up of:

Code position Gives information about the ...

1 sales denomination
2 version

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Practical Information, Product Identity

Serial number The serial number is used for identification of an individual pump/mixer.
This is an example of a serial number

NP 3085.183 - 951 0163

1 2 3 4
Table: This table explains what the serial number is made up of:

Product code position Gives information about the ...

1 product code

2 production year

3 production cycle
4 running number

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Practical Information, Order parts

Order parts

Order When order spare parts, state serial number of the product, spare part number and
quantity.

Requirements Genuine ITT Flygt parts must always be used for repairs if the product is to fulfill
requirements and obtain official approval.

Qualification Only ITT Flygt or Flygt-authorized service personnel may undertake repair work on
of personnel Ex-approved products.

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Dimensional drawings

Dimensional drawings
Overview

Table of This chapter contains the following topics:

Contents
Topic
Lifting Davit........................................................................................................ 25
Davit 320 ...................................................................................................... 25
Davit 600 ...................................................................................................... 26
Measurements for Brackets ................................................................................ 27
Single Guide Bar System ............................................................................... 27
Mixer ................................................................................................................. 31
Single Guide Bar With Jet Ring ...................................................................... 31
Single Guide Bar With Vortex Shield ............................................................... 32
Single Guide Bar Without Jet Ring.................................................................. 33
Flange Mounting ........................................................................................... 34
PP Installation ............................................................................................... 35

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Dimensional drawings, Lifting Davit

Lifting Davit

Davit 320

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Dimensional drawings, Davit 600

Davit 600

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Dimensional drawings, Measurements for Brackets

Measurements for Brackets

Single Guide Bar System

Davit holder —
floor mounted
A D

C B
D

This table shows how to position the floor mounted davit holder.

Position A B C D
Guide bar Dimension (mm)
system
50x50 Ø14 15 150 180

100x50
100x100 Ø18 20 300 340

150x100

Davit holder —
wall mounted B
D

C
A B

E
F H
G

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Dimensional drawings, Single Guide Bar System

This table shows how to position the wall mounted davit holder.

Posi- A B C D E F G H
tion
Guide Dimension (mm)
bar
sys-
tem
50x50 Ø14 27 300 70 60 155 210 27,5

100x50
100x100 Ø18 50 600 100 110 190 260 35

150x100

Upper bracket
B
C D E

A F

This table shows how to position the upper bracket.

Position A B C D E F
Guide bar Dimension (mm)
system
50x50 Ø14 43 70 155 210 27,5

100x50
100x100 Ø18 50 100 190 260 35

150x100

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Dimensional drawings, Single Guide Bar System

Upper bracket
— under floor B
alternative C D E

A F

This table shows how to position the upper bracket when mounted under floor.

Posi- A B C D E F G
tion
Guide Dimension (mm)
bar
system
50x50 Ø15 190 150 20 15 150 275

100x50
100x100 Ø19 230 190 20 20 190 335

150x100

Lower bracket
W A

C D
B

B
E G
F

W = bracket fixed to the wall.

B = Bracket fixed to the bottom.
This table shows how to position the lower bracket.
Posi- A B C D E F G
tion
Guide Dimension (mm)
bar
system
50x50 Ø14 15 147,5 190 160 215 27,5

100x50

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Dimensional drawings, Single Guide Bar System

100x100 Ø18 25 185 250 200 290 45

150x100

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Dimensional drawings, Mixer

Mixer

Single Guide Bar With Jet Ring

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Dimensional drawings, Single Guide Bar With Vortex Shield

Single Guide Bar With Vortex Shield

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Dimensional drawings, Single Guide Bar Without Jet Ring

Single Guide Bar Without Jet Ring

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Dimensional drawings, Flange Mounting

Flange Mounting

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Dimensional drawings, PP Installation

PP Installation

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Install Lifting System

Install Lifting System

Overview
Introduction

This chapter describes how to mount the lifting system.

Table of This chapter contains the following topics:

Contents
Topic
EU Declaration of Conformity.............................................................................. 37
Mount Lifting Davit ............................................................................................. 38
Mount Lifting Equipment ..................................................................................... 42

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Install Lifting System, EU Declaration of Conformity

EU Declaration of Conformity

Lifting system This is a EU declaration of conformity valid for lifting davits.

Reference The EU declaration of conformity valid for machines is attached separately together with
the machine.

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Install Lifting System, Mount Lifting Davit

Mount Lifting Davit

Introduction This section describes how to mount the lifting davit.

The instruction is a general description which includes lifting davit 300, 320 and 600 and
illustrations shall bee seen as examples of the davits.
For measurements, see Dimensional Drawings.

NOTE! All mounting to the floor shall be made with chemical anchor bolts from ITT Flygt.

Lifting Davit
300, 320 & 600

This is an illustration of a Lifting Davit.

4 2

6 6

List: This is a list of the parts of the lifting davit:

1. Lifting davit pipe
2. Lifting davit unit
3. Lock plate unit
4. Operating bar
5. Sleeve
6. Sleeve
7. Davit holder, floor mounted
8. Davit holder, wall mounted

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Install Lifting System, Mount Lifting Davit

Instruction

Follow these steps to mount the Lifting Davit; 300, 320 or 600.
Step Action Illustration

1 • Position the davit holder.

A = Minimum distance 65 mm,
recommended 125 mm.
• Fasten the davit holder with chemical
anchors.
Maximum torque = 60 Nm.

A
A

2 If required: Adjust the pipe to proper

length. Remove the sleeve and cut the
pipe.
Reassemble the sleeve.

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Install Lifting System, Mount Lifting Davit

Step Action Illustration

3 • Check that the sleeves are positioned

at the pipe end and at the top of the
davit holder
• Fit the lifting davit pipe unit in the davit
holder.

4 Fit the lifting davit unit onto the bracket.

Secure the unit with a pin.

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Install Lifting System, Mount Lifting Davit

Step Action Illustration

5 Fix the lifting davit unit and the lock plate

unit together with a pin and secure it.

6 Choose a suitable hole in the lock plate

unit and fit it with the davit pipe. Secure
the unit with a pin.

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Install Lifting System, Mount Lifting Equipment

Mount Lifting Equipment

Introduction This section describes how to mount the lifting equipment such as winch, chain, block and
tackle to the lifting davit.

NOTE! All mounting to the floor shall be made with chemical anchor bolts from ITT Flygt.

The winch may be mounted to the

• davit pipe or
• davit unit

Maximum load The winch have a maximum load of 320 kg.

— winch For each winch there is a purpose–made winch bracket.

Instruction

Follow these steps to mount the lifting equipment to the davit.

Step Action Illustration

1 Fit the winch to the bracket by using the provided

bolts.
Check that the “top” and “bottom” marks are
correctly positioned.

2 Fit the winch to the davit pipe or the davit unit

in a suitable position where the height setting is
easily adjustable.
Check
• that the center of the drum is in line with
the center line of the davit arm. Lock it
in position on the davit pipe by using the
clamping nuts.
• that the winding handle is on the right side.

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Install Lifting System, Mount Lifting Equipment

Step Action Illustration

3 Place the cord pulley or block and tackle in

position.
Check that the handling chain or wire is vertical.

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Install Lifting System, Mount Lifting Equipment

Chain, Block This table shows the available lengths and maximum loads.
and Tackle Lifting equipment Maximum load Available lengths

Kg m
Calibrated lifting chain 500 5, 9 or 20
Chain links with hook and 500 0.75
shackle
Corner block 400
Block and tackle 500

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 Vendor Manual - Submersible Mixer Flygt Model 4650 Installation, Operation and Maintenance Manual

Install Guide Bar System

Overview
Introduction

This chapter describes how to install the guide bar systems.

NOTE! All mounting to the floor shall be made with chemical anchor bolts from ITT Flygt.

Table of This chapter contains the following topics:

Contents
Topic
Mount Single Guide Bar system .......................................................................... 46
Mount without intermediate support ................................................................ 46
Mount with intermediate support..................................................................... 50

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Install Guide Bar System, Mount Single Guide Bar system

Mount Single Guide Bar system

Introduction This chapter describes how to install a single guide bar system with or without intermediate
support.

Mount without intermediate support

Illustration

This is an illustration of a single guide bar system up to 6 m, without intermediate support.

1
2
9
2

4
7
6
5

List: This is a list of the general parts of the single guide bar system without intermediate
support:
1. Upper guide
2. Upper bracket
3. Guide bar
4. Lower guide
5. Lower bracket pin
6. Lower guide pin

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Install Guide Bar System, Mount without intermediate support

7. Lower bracket
8. Upper guide retaining bolt
9. Upper bracket, under floor

NOTE! The lower bracket may be fixed to the bottom or the wall of the tank.

Instruction

Follow these steps to install single guide bar system without intermediate support:
Step Action Illustration

1 Position the guide brackets.

A = minimum 65 mm, recommended 125 mm.

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Install Guide Bar System, Mount without intermediate support

Step Action Illustration

2 Fix the upper bracket.

3 Check
• the position of the lower bracket.
• that the pin in the lower bracket is in line with
the center line of the upper bracket. Use a
plumb line.
Wall mounted bracket: It may be necessary to put
metal shims under one of the brackets to achieve a
vertical axis of rotation.

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Install Guide Bar System, Mount without intermediate support

Step Action Illustration

4 Fix the lower bracket.

5 Fit the lower guide to the lower bracket by positioning

it on the pin.

6 • Measure the distance between the lower and

the upper guides.
• Subtract 10 mm from the measurement and cut
the guide bar there
Note! Make sure that the cut end of the guide bar
points downwards.

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Install Guide Bar System, Mount with intermediate support

Step Action Illustration

7 • Insert the bar to the lower guide.

• Insert the upper guide to the bar.
• Fit the bolt, but do not tighten.

8 • Turn the guide bar unit to required angle.

• Fix the angle H with the indexing screw.
• Mount the shackle to the upper bracket. H
See, Positioning the mixer, for correct angle setting.

9 Install the mixer on the single guide bar system.

Mount with intermediate support

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Install Guide Bar System, Mount with intermediate support

Illustration

This is an illustration of a single guide bar system over 6 m with intermediate support.

10
12

3
2 3

11

3,
9, 13
13
8 16

4
6
5

List: This is a list of the general parts of the single guide bar system with intermediate
support:
1. Upper guide
2. Upper bracket
3. Guide bar
4. Lower guide
5. Lower bracket pin
6. Lower guide pin
7. Lower bracket
8. Intermediate bracket
9. Extension bar
10. Upper guide retaining bolt
11. Intermediate guide retaining bolt
12. Upper bracket, under floor — alternative
13. Extension bar — alternative

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Install Guide Bar System, Mount with intermediate support

NOTE! The lower bracket may be fixed to the tank bottom or to the wall.

Instruction

Follow these steps to install single guide bar system with intermediate support:
Step Action Illustration

1 Position the guide brackets.

A = minimum 65 mm, recommended 125 mm.

2 Fix the upper bracket.

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Install Guide Bar System, Mount with intermediate support

Step Action Illustration

3 Check
• the position of the lower bracket.
• that the pin in the lower bracket is in line with
the center line of the upper bracket. Use a
plumb line.
Wall mounted bracket: It may be necessary to put
metal shims under one of the brackets to achieve a
vertical axis of rotation.

4 Fix the lower bracket.

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Install Guide Bar System, Mount with intermediate support

Step Action Illustration

5 • Position the intermediate bracket.

• Check that it is in line with the lower and upper
brackets by using a plumb line.
• If, necessary, add shims under the brackets to
align the brackets.
• Fix the intermediate bracket.

6 Fit the lower guide to the lower bracket by positioning

it to the pin.

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Install Guide Bar System, Mount with intermediate support

Step Action Illustration

7 • Measure the distance between the intermediate

bracket and the lower guide.
• If necessary, cut the bar.

8 • Insert the lower extension bar to the lower

guide.
• Fit the bolt, but do not tighten.

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Install Guide Bar System, Mount with intermediate support

Step Action Illustration

9 • Measure the distance between the edge of the

lower extension bar and the upper guide.
• Subtract 10 mm from the measurement and cut
the guide bar there.
Note! Make sure that the cut end of the guide bar
points downwards.

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Install Guide Bar System, Mount with intermediate support

Step Action Illustration

10 • Insert the guide bar to the lower guide.

• Insert the upper guide to the bar.
• Fit the bolt, but do not tighten.

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Install Guide Bar System, Mount with intermediate support

Step Action Illustration

11 • Turn the guide bar unit to required angle.

• Fix the angle H with the indexing screw.
• Mount the shackle to the upper bracket.
See chapter Positioning the mixer, for correct angle
setting.
+/-60

12 Install the mixer on the single guide bar system.

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Install the Mixer

Overview
Introduction

This chapter describes how to install the mixer.

NOTE! All mounting to the floor shall be made with chemical anchor bolts from ITT Flygt.

Table of This chapter contains the following topics:

Contents
Topic
Install on a Single Guide Bar System................................................................... 60
Install on a Sloping Bottom ................................................................................. 63
Install with Flange .............................................................................................. 65

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Install the Mixer, Install on a Single Guide Bar System

Install on a Single Guide Bar System

Introduction This section describes how to install the mixer on a single guide bar system.
When positioning the mixer there are three parameters to be observed:
• H = Height from tank bottom
• α H = Horizontal angle
• α V = Vertical angle
H and α H are set at the stage of placing the unit on the guide bar system.
For angle position data and instructions, see Positioning the Mixer.

Instruction

Follow these steps to install the mixer on the guide bar system.
Step Action Illustration
1 • Attach the retaining chain or wire to the
mixer by means of the shackle.
• Attach the lifting chain or wire to the unit.
• Fit a support grip on the power cable.
• Place cable holders on the power cables at
every 1.5 m.

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Install the Mixer, Install on a Single Guide Bar System

Step Action Illustration

2 • Raise the mixer and rotate it by using the
davit handle.
• Lower the mixer.

3 Position the mixer on the guide bar to the given

height “H” from the tank bottom or to the support.
See, Positioning the mixer, for correct angle
setting.

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Install the Mixer, Install on a Single Guide Bar System

Step Action Illustration

4 Lower the retaining chain or wire and the power
cable.
Note! The power cable must not carry the weight
of the mixer.

5 The mixer is now ready to be connected to the

power supply.
See, Electrical Installation

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Install the Mixer, Install on a Sloping Bottom

Install on a Sloping Bottom

Introduction This chapter describes how to install the mixer on a sloping bottom.
For measurements, see Dimensional Drawings.

Illustration This illustration shows a tank with sloping bottom.

If the tank bottom slopes the installation procedure of the guide system needs to be
modified:
• A larger distance is needed between the guide bar and the wall in order to allow
turning of the lower bracket.
• An intermediate wall spacer is needed to keep the guide bar’s distance from the wall.

This table shows examples of how to place the intermediate wall spacer (1).
Horizontal floor mounted davit holder Davit holder placed outside the tank

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Install the Mixer, Install on a Sloping Bottom

General parts

This table shows the general parts of a guide bar installation in a tank with sloping bottom.
Pos. Description Illustration
1 Guide bar
2 Lower guide
3 Lower bracket
1

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Install the Mixer, Install with Flange

Install with Flange

Introduction Flange mounted mixer is a unique method for installing mixers in tanks where guide bar or
bottom stand is not applicable.
The flange mounted mixer consists of
• a mixer with fixing plate and
• a flange cover, manufactured locally.
Contact your nearest ITT Flygt representative for information.

Illustration

This illustration shows a mixer with a fixing plate.

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Positioning the Mixer

Positioning the Mixer

Overview

Table of This chapter contains the following topics:

Contents
Topic
General description ............................................................................................ 67
Clearance.......................................................................................................... 68
Horizontal angle ................................................................................................. 69
Vertical angle ..................................................................................................... 72

Reference For more information, see Mixer Positioning Principles (part.nr: 892731).

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Positioning the Mixer, General description

General description

Parameters When positioning the mixer there are three parameters to be observed:
• H = Height from tank bottom
• α H = Horizontal angle
• α V = Vertical angle
H and α H are set at the stage of placing the unit on the guide bar system.

Illustration

This illustration shows the three parameters to be observed.

H
V

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Positioning the Mixer, Clearance

Clearance

Propeller This table shows the minimum propeller clearance in connection with the
clearance installation work that should be observed.
Distance between the... should not be less Illustration
than...
A peak position of the 300 mm
propeller blade and
• the bottom of the
tank and/or
• the side wall
B peak position of the Exception: In thick
propeller blade and media and very good
B
• the liquid level flow condition or lower
motor load the distance
can be 300 mm. C

C propeller blade and the the dimension of the

background wall propeller diameter.

Distance between the propeller and should not be less than...

the...
side wall 0.5 times the propeller diameter.
bottom 1 propeller diameter.
background wall 1.5 times the propeller diameter.

Obstacles and walls downstream of mixer: The clear distance downstream of the mixer
should be at least 10 times the propeller diameter.

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Positioning the Mixer, Horizontal angle

Horizontal angle

Instruction Follow these steps to set the horizontal angle.

Step Action Illustration

1 Set the angle by rotating the

guide bar.

See table for α H angle

identification.

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Positioning the Mixer, Horizontal angle

Step Action Illustration

2 Place the indexing screw in the

corresponding hole.
180° 0°

90°

0°

6 1
5 2
4 3

0°

A D
B C

3 Place the support grip in position

on the power cable and attach it
to the shackle.

NOTE! The support

grip is
imperative
when the
mixer is held
in position by
wire and not
by chain.

4 The mixer is now ready to be

connected to the power supply.

See, Electrical Installation

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Positioning the Mixer, Horizontal angle

Table 1: α H This table gives an angle identification of mixer orientation α H from 0–90 degree.
0–90
αH Letter Numeral Other possible combinations

0 A 1 Letter Numeral
10 B 1 – –
20 A 2 – –
30 B 2 – –
40 A 3 – –
50 B 3 – –
60 A 4 – –
70 B 4 C 1
80 A 5 D 1
90 B 5 C 2

Table 1: α H This table gives an angle identification of mixer orientation α H from 100–180 degree.
100–180
αH Letter Numeral Other possible combinations

Letter Numeral
100 A 6 D 2
110 B 6 C 3
120 D 3 – –
130 C 4 – –
140 D 4 – –
150 C 5 – –
160 D 5 – –
170 C 6 – –
180 D 6 – –

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Positioning the Mixer, Vertical angle

Vertical angle

General Orientation is by means of a set of rollers situated on the rear guide of the mixer.

1 2

Instruction Follow these steps to set the vertical angle.

Step Action Illustration

1 Set the desired α V angle, by M

placing the rollers according to +
the illustration. 2
V 0°
The roller 1 is always used in -
2
front of the guide bar.

For correct lifting equipment 1 +10° 2

position see Dimensional
Drawings to obtain the M -10° 2 1

measurement. +20°

Note that different 1 2

measurements apply for mixer
with or without jet ring. 2 1
-20°

2 The mixer is now ready to be

connected to the power supply.

See, Electrical Installation

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Electrical Installation
Overview

Table of This chapter contains the following topics:

Contents
Topic
Power Supply .................................................................................................... 74
Connection ........................................................................................................ 75
Cable Connection Diagrams ............................................................................... 76
Cable Connection to Controller ........................................................................... 79

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Electrical Installation, Power Supply

Power Supply

NOTE! Fused rating and cable shall be selected in accordance with local rules and regulations.

Cables Always check that the cables are in perfect condition before using them.
• Make sure that the cable does not have any sharp bends and is not pinched.
• If the outer sheath is damaged, contact a Flygt service shop to replace the cable.
• Make sure that the conductors not in use are isolated
• If a variable-frequency-drive (VFD) is used, make sure that the shielded cable (type
Screened Subcab) is used according to the European CE requirements. Reference:
For more information contact your Flygt representative VFD-supplier.

Information on See the product’s data plate.

current
NOTE! Pay attention to the voltage drop in long cables! The motor’s rated voltage is the
voltage measured at the terminal board in the product.

Overload The Starting current in direct-on-line starting can be up to six to ten times higher than the
protection rated current. Therefore, make sure that
• the fuses or circuit breakers are of proper rating.
• the overload protection (motor protection breaker) for direct-on-line starting are set to
the motor rated current stated on the data plate.

Possible When the mixer is connected to the public mains it may cause flicker of incandescent
Disturbances lamps when starting. In this case the supply authority should be notified before installing
the mixer.

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Electrical Installation, Connection

Connection

Earthing Make sure that the product is correctly earthed.

The earth conductor shall always be longer than the phase conductors. Rationale: If the
motor cable is jerked loose by mistake, the earth conductor shall be the last conductor to
be disconnected from its terminal. This applies to both ends of the cable.

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Electrical Installation, Cable Connection Diagrams

Cable Connection Diagrams

SUBCAB 4GX
/ SUBCAB
AWG Y and
D Connection

This is an illustration of how to connect the cable leads and the stator leads.
Y Connection D Connection
GC L1 L2 L3 T1 T2 GC L1 L2 L3 T1 T2

T1 T1

T2 T2

SUBCAB® SUBCAB® SUBCAB® SUBCAB®

T1 T2 T1 T2 T1 T2 T1 T2

GC GC

L1 L2 L1 L2
L3 L3

W2 U2 V2 W2 U2 V2
T1 T1

T2 T2
U1 V1 W1 U1 V1 W1

W2 U1 V1 U2 W1 V2 W2 U1 V1 U2 W1 V2

Bild 47 Bild 43

This table explains the colors of the leads.

Mains SUBCAB Cable SUBCAB AWG Terminal board
lead Cable lead
L1 Brown Red U1
L2 Black Black W1
L3 Grey White V1
Yellow/Green Yellow/Green

Groundcheck GC Yellow
Control

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Electrical Installation, Cable Connection Diagrams

T1 T1 Orange T1
T2 T2 Blue T2
Stator leads connection: Terminal board

Stator lead
U1, red U1
W2, black W2
V1, brown V1
U2, green U2
W1, yellow W1
V2, blue V2

Screened
SUBCAB
6–Leads Y and
D Connection

This is an illustration of how to connect the cable leads and the stator leads.
Y Connection D Connection
L1 L2 L3 T1 T2 L1 L2 L3 T1 T2

T3 T3
L1 L2 L3 T1 T2 T4 L1 L2 L3 T1 T2 T4

SUBCAB® SUBCAB®

T4 T4
T1 T2 T3 T1 T2 T3

L1 L3 L2 L1 L3 L2

W2 U2 V2 W2 U2 V2
T1 T1

T2 T2
U1 V1 W1 U1 V1 W1

W2 U1 V1 U2 W1 V2
W2 U1 V1 U2 W1 V2

Bild 47a
Bild 47b

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Electrical Installation, Cable Connection Diagrams

This table explains the colors of the leads.

Mains SUBCAB Cable lead Terminal board
L1 Brown U1
L2 Black W1
L3 Grey V1
Screen twisted together

Groundcheck GC
Control
T1 T1 T1
T2 T2 T2
T3 T3 End sleeve

Not in use Not in use

T4 T4 End sleeve

Not in use Not in use

Stator leads connection:

Stator lead
U1, red
W2, black
V1, brown
U2, green
W1, yellow
V2, blue

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Electrical Installation, Cable Connection to Controller

Cable Connection to Controller

This illustrates how to connect the product’s power cable to the controller.

L2

L1 L3

L1 L2 L3

Main leads Type of cable

SUBCAB SUBCAB AWG

Silicon

HCR
Green/Yellow Green/Yellow

L1 Brown Red
L2 Black Black
L3 Grey White

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Set up the Controller

Set up the Controller

Thermal The terminal switches are incorporated in the stator and shall be connected according
Switches to the cable chart. Flygt recommends that they are connected to 24 V over the separate
fuses to protect the automatic equipment.

Additional The terminal A plate in the junction box shows if the product is equipped with other
sensors sensors than thermal contacts.

This table gives an overview of possible additional sensors for this product.
Sensor Description
CLS-30 A leakage sensor that
• senses water in the oil housing, and
• initiates an alarm when the oil contains 30% water.
Not applicable to Ex-approved pumps.

WARNING!
Sensor body is made of glass!

Handle with care!

FLS A small float switch for sensing water in the stator housing.

Design suitable for products in vertical installations.

Monitoring If intermittent operation is prescribed (see data plate), the product shall be provided with
relay control equipment that provides it. The Mini-CAS II is a monitoring relay to which the
CLS and/or FLS are connected.

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First Start-Up
Before starting Follow these steps when test-running the mixer.
Step Action Illustration
1 Check:
• that there is oil in the oil casing
• that the propeller can be rotated by
hand
• that the cable entry is securely
tightened
• that the machine is fixed to the guide
bar
NOTE! Maximum starts and
stops are 30 times.

2 Check the direction of rotation.

The propeller shall rotate clockwise as

viewed from the motor side.

WARNING!
Watch out for the
propeller and for the
starting jerk, which can
be powerful.

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Trouble Shooting

Trouble Shooting
Overview
Trouble shooting shall be done with the power supply disconnected and locked off, except
for those checks which cannot be performed without voltage.

Always make sure that there is no one near the mixer when the power supply is turned on.

When trouble shooting on the electrical equipment use:

• a universal instrument multimeter (VOM)
• a test lamp (continuity tester) and
• wiring diagram.

NOTE! Electrical work shall be performed by an authorized electrician.

Follow local safety regulations and observe recommended safety precautions.

Table of This chapter contains the following topics:

Contents
Topic
If the Mixer Fails to Start ..................................................................................... 83
If the Mixer Starts but Motor Protection Trips........................................................ 84
If the Mixer Starts, Stops and Starts in a Rapid Sequence .................................... 85

Use the following checklists as an aid at trouble shooting. It is assumed that the mixer and
installation have formerly functioned satisfactorily.

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Trouble Shooting, If the Mixer Fails to Start

If the Mixer Fails to Start

Follow these steps to troubleshoot the mixer when it fails to start.
No Question No Yes
1 Is an alarm signal indicated on Check question No 2. • Check that the overload
the control panel? protection is reset.
• Check the thermal switches.
If the thermal switches are out
of order, contact an ITT Flygt
service shop.
2 Can the mixer be started Check question No 3. • Check that all connections
manually? are intact.
• Check relay and contactor
coils.
• Check that the control switch
(Man/Auto) makes contact in
both positions.
3 Is the installation receiving Check that Check question No 4
voltage? • the main power switch is
on.
• there is control voltage to
the start equipment and its
fuses are intact.
• there is voltage in each
phase of the supply line.
• all fuses have continuity
and are tight.
• the overload protection is
reset.
• the motor cable is not
damaged.

4 Is the propeller stuck? Check question No 5 • Check that the propeller

rotates easily by hand.
WARNING! Disconnect power • Clean the propeller.
before checking the propeller.
5 Does the fault still exist? Contact an ITT Flygt service
shop.

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 Vendor Manual - Submersible Mixer Flygt Model 4650 Installation, Operation and Maintenance Manual

Trouble Shooting, If the Mixer Starts but Motor Protection Trips

If the Mixer Starts but Motor Protection Trips

Follow these steps to trouble shoot the mixer when the mixer starts but the motor protection
trips.
No Question No Yes
1 Is the motor protection set too Check question No 2. Set the motor protection according
low? to the data plate.
2 Is the propeller difficult to rotate Check question No 3 • Clean the propeller.
by hand? • Check that the propeller size
WARNING: disconnect power is correct.
before checking the propeller! If none of these actions helps,
contact an ITT Flygt service shop.
3 Is the installation receiving full • Check the motor fuses. Check question No 4.
voltage on all three phases? • Notify an authorized
electrician.
4 Have all the phase currents Check question No 5. Contact an ITT Flygt service shop.
the same value or are they too
high?
5 Is the rated speed in Check question No 6. Contact an ITT Flygt service shop.
accordance with the data
plate?
6 Is the density of the liquid too Check question No 7. • Dilute the liquid.
high? • Change the propeller blades or
to a more suitable mixer.
• Contact an ITT Flygt service
shop.
7 Fault on the overload Check question No 8. Replace the overload protection.
protection?
8 Does the fault still exist? - Contact an ITT Flygt service shop.

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 Vendor Manual - Submersible Mixer Flygt Model 4650 Installation, Operation and Maintenance Manual

Trouble Shooting, If the Mixer Starts, Stops and Starts in a Rapid Sequence

If the Mixer Starts, Stops and Starts in a Rapid Sequence

If the contactor’s selfholding function break, check
• the contactor connections.
• the voltage in the control circuit in relation to the rated voltage on the coil.
If the contactor’s selfholding function is ok and the fault still exist, contact an ITT Flygt
service shop.

WARNING!
Do not override the motor protection repeatedly if it has tripped!

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 Vendor Manual - Submersible Mixer Flygt Model 4650 Installation, Operation and Maintenance Manual

Preventive Maintenance

Preventive Maintenance
Topics in this Topic in this section is:
section • Intermediate Service

Maintenance ITT Flygt recommends a preventive maintenance program based on Intermediate and
Program Major Service at regular intervals. For Major Service instructions, refer to the Service
and Repair Manual.
For applications other than sewage water or for specific operating conditions, other service
intervals may be recommended.

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 Vendor Manual - Submersible Mixer Flygt Model 4650 Installation, Operation and Maintenance Manual

Preventive Maintenance, Intermediate Service

Intermediate Service
For standard sewage applications, where the temperature of the pumped liquid is 40°C or
less, an Intermediate Service should be performed every 2 years.

Mixer This table shows what to inspect at intermediate service concerning the mixer.

Item Action
Junction box Check that it is clean and dry.
Terminal board Check that the connections are properly
tightened
Insulation check • Check that the resistance between
earth (ground) and phase lead is more
than 5 M Ω.
• Conduct phase-to-phase resistance
check.
Cable Check that the rubber seating (jacket) is
undamaged.
Seal housing • Check oil level. Fill up with new oil if
necessary.
O-rings • Replace the O-rings of the filling plugs
and at the junction cover and
• Grease new O-rings.
Thermal contacts Check the resistance.

Normally closed circuit; interval 0–1 Ω.

Thermistor Check the resistance 20–250 Ω.

Measuring voltage max. 2 V DC.

Rotation direction Check the rotation of the mixer.
Lifting equipment Check the screws and the condition of the
lifting equipment.
Lifting device Check that local safety regulations are
followed.
Voltage and amperage Check running values.

Mixer site This table shows what to inspect at intermediate service concerning the mixer site.

Item Action
Electrical cabinets/panels Check that they are clean and dry.
Connection to power Check that the connections are properly
tightened.
Overload and other protections Check correct settings.
Personnel safety Check guard rails and other protective
devices.

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 Vendor Manual - Submersible Mixer Flygt Model 4650 Installation, Operation and Maintenance Manual

Mixer 4650
896508/6.0 - 20080328
www.flygt.com © ITT Flygt AB, Printed in Sweden

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