U IKA magiclab OPERATING MANUAL. Reg. Nr

Transcription

1 U IKA magiclab OPERATING MANUAL EN Reg. Nr

2 2 magiclab 09/12

3 DECLARATION OF CONFORMITY EC Declaration of Conformity as defined by EC Machinery Directive 2006/42/EC, Appendix II A Herewith we: IKA WERKE GMBH & Co. KG Janke und Kunkel- Str. 10 D Staufen declare that the below named machine on account of its design and construction as well as in the version we offer for sale complies with the relevant underlying safety and health requirements stipulated by the EC directives. In case of a modification of the machine which is not co-ordinated with us this declaration will no longer be valid Designation of the machine: magiclab Relevant EC directives: Applied harmonised standards: 2006/42/CE (machinery directive) 2006/95/CE (Low voltage directive) EN ISO (Safety of machinery) EN ISO (Safety of machinery) EN ISO 13857(Safety of machinery) EN 349 (Safety of machinery) EN (Safety of machinery) EN (Electrical equipment for measurement, control and laboratory use) EN (Safety requirements of laboratory devices) EN does not apply for the Controller U Date: Manufacturer s signature: Information on the undersigned: Peter Wanninger Managing Director Authorised person for documentation: Karen Klem magiclab 09/12 3

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5 OPERATING MANUAL EN 1. For your safety General dangers Intended use Safety precautions General safety instructions Basic safety precautions during normal operation Basic safety instructions during service and maintenance Work on the electrical equipment Observe the environmental protection regulations Other dangers Specifications Electrical data Unpacking Description Basic unit and modules Modular design Assembly information Basic unit Module UTL Module DISPAX REACTOR DR Module colloid mill MK Module MHD Module CMS Module UTC Brief test Working with the machine Information on working with product Operation using flow-through processes Accessories for circulation processes MicroPlant Connector design Connection of the customer Heating / Cooling connections Starting the machine Switching the machine off Calculation of the throughput rate Operation Installation Functions Operation of the panel Maintenance Shaft seal Changing O-rings Generators Dispersion Tools UTC NK for module UTC Bearing Drive shaft Electrical equipment Cleaning Basic machine Controller housing Dispersion tools and product contacting parts Troubleshooting magiclab 09/12 5

6 10.1 Failure of magiclab controller Dimension sheets MODULE UTL MODULE DR MODULE MK MODULE MHD MODULE CMS MODULE UTC Micro Plant Scale Up IKA magiclab 09/12

7 1. For your safety 1.1 GENERAL DANGERS Observe all pertinent safety instructions and directives, as well as work safety and accidentprevention regulations for laboratory use. Used correctly, the machine itself does not pose any danger. Installation or combination with other machinery can, however, present dangers which are unintentional on the part of the manufacturer. We would like to draw your attention to the fact that the user must observe work area guidelines when operating the machine. 1.2 INTENDED USE In order to prevent damage to persons or machinery, the machine may only be operated in accordance with its intended use. For intended use, magiclab must be installed on a stable, even and non-slip laboratory table. Do not install it on wooden or synthetic tabletops. The magiclab has a modular design, i.e. the machine can be operated as basic unit with module UTL or can be turned into differently operating machines using modules. The basic unit magiclab as well as the modules DISPAX-REACTOR DR and colloid mill MK are designed for dispersing mixtures during the liquid, pumpable phase. Dispersions include the area of emulsions (liquid/liquid), suspensions (liquid/solid), and aerosols (gaseous/liquid). The machine is also suitable for both homogenisation and solution of colloid substances. In order to ensure protection of the machine against foreign bodies such as screws, stones, welding beads etc. on the mixing tools, it is recommended that a sieve or filter is placed in front of the machine prior to feeding in substances. The magiclab including the MHD and CMS modules is designed for mixing and homogenising liquid substances with powdery substances. The magiclab with dispersing tools S 25 is a dispersion machine which, in connection with a dispersion tool, manufacture emulsions and dispersions in batch. The dispersion machines should be operated on a laboratory stand. For working with UTC-module use an adequate stand for the weight of the magiclab. Important In order to avoid damage to the magiclab controller by overheating, a minimum distance of 10 cm should be kept between the intake and exhaust air grids of the magiclab controller and other objects. magiclab 09/12 7

8 1.3 SAFETY PRECAUTIONS The machine (including the subassemblies) has been designed and built considering a danger analysis and after careful selection of the harmonised standards to be observed as well as further technical specifications. It corresponds to the latest state of the technology and allows for maximum safety during operation. The safety of machinery, however, can only be realised during operation if all required measures have been taken. It is the user's duty of care to plan these measures and to check their realisation. The user must especially ensure that, the machine is only operated in accordance with its intended use, the machine is only operated in a technically perfect and operational condition and that in particular the functional reliability of the safety equipment is checked at regular intervals, required personal protective equipment for operating, maintenance, and repair personnel is available and will be worn, the operating instructions are always legible and complete at the site of operation of the machine, the machine is exclusively operated, maintained, and repaired by qualified and authorised personnel, this personnel, at regular intervals, shall receive instruction regarding all questions concerning work safety and environmental protection and that they are familiar with the operating instructions and in particular with the included safety instructions, all safety signs and warnings attached to the machine itself will not be removed and made illegible. The following operating instructions give special safety instructions in order to refer to residual risks which can not be avoided during operating or maintenance. These residual risks include dangers for persons, product, machine and environment. The most important aim of the safety instructions is to prevent personal injury. The meaning of the safety of the different safety instructions is described below. The respective symbol used can not replace the text of the safety instruction. Therefore, always read the text completely Danger Warning This symbol indicates a imminent hazardous situation for life and health of persons. Nonobservance of these safety instructions leads to serious effects on life and health, including mortal injuries. This symbol indicates a possibly hazardous situation for life and health of persons. Nonobservance of these safety instructions can lead to serious effects on life and health, including mortal injuries. 8 magiclab 09/12

9 This symbol indicates a possibly dangerous situation. Nonobservance of these safety instructions can lead to minor injuries or damage to the machine or the surroundings. Caution This symbol indicates a risks due to hot surfaces. Nonobservance of these safety instructions can lead to burns or damage to the machine or the surroundings. Hot surface Important Under this symbol important information is given for appropriate use of the machine. Nonobservance of these instructions can lead to disturbance of the machine or the surroundings. Under this symbol information for use are given. This information will help you to make optimum use of all functions of your machine. Note magiclab 09/12 9

10 1.4 GENERAL SAFETY INSTRUCTIONS Observe all pertinent safety instructions and directives, as well as work safety and accident-prevention regulations for laboratory use. Danger Modifications of the system and parts of it are only allowed with written approval of IKA. Otherwise the warranty and the declaration of conformity will become void! Danger Danger Danger Danger due to electrical current! Contact with electrical lines or components can have serious effects on your health or even life. Only persons with electrical/electronical training are allowed to work on the electronical components of the machine. If connected to the power supply, the system is live. Starting the machine without any module and connecting devices has serious effect on health and life due to the rotating shaft and the medium in the machine. Only start the machine when the modules and connecting lines are mounted completely. Subject to technical modifications. Note 10 magiclab 09/12

11 1.5 BASIC SAFETY PRECAUTIONS DURING NORMAL OPERATION Inadverted starting of the machine has serious effect on health and life. Before changing the modules unplug the mains plug and secure the machine against inadverted starting! Danger Danger The machine may only be operated by trained and authorised persons who are familiar with the operating instructions (also of the subassemblies) and who are able to follow these instructions! The magiclab may not be used to process inflammable or explosive media. There may be electrostatic discharges between medium and dispersion tool which could pose a direct danger. Do not use the magiclab in explosion proofed area. Danger Danger Danger due to electrical current! If the magiclab is used at media temperatures above 65 C the electrical cables must be protected against any contact with medium to avoid damage of electrical cables. Disregarding this safety instructions has serious effects on health or life. Using damaged hose lines has serious effects on health and life. Replace all hose lines at regular intervals as a preventive maintenance measure, even if no damages can be recognised! (Observe the manufacturers' indications!) Danger Warning After assembly works and before the drive is switched on, check the clearance of the machine's drive shaft by manually turning it. Turning the machine's drive shaft may have serious effects on health and life. When turning the shaft manually, protect the drive against inadvertent starting! magiclab 09/12 11

12 Danger of burns by hot surface! If the duty ratio is 100% with an outside temperature above 35 C, the motor outside temperature rises above 65 C. Avoid contact to the motor casing. Hot surface Hot surface Danger of burns by hot surface! If the working chamber is brought to a specified temperature, above 65 C the danger of burns exists at the non-insulated parts of the reservoir and the supply lines. In this case, the hot parts must be provided with a touch guard by the user. Before switching the machine on, inform yourselves about the correct behaviour in case of failures (see chapter 10)! Important The machine may only run dry for a few seconds, otherwise the rotary shaft seal on the product side will be destroyed. Important Important Important Important 5 Important Avoid knocks and impacts on the end of the shaft and the thread. Even minor, invisible damage can lead to imbalance and even affect the radial run-out of the shaft. Carefully handling guarantees safety working and the long life of the equipment. The machine with module MK may only be switched on after radial gap adjustment. Otherwise there is a risk of damaging the machine. Running the machine only with dry substances causes damage to the machine. Avoid supplying and processing pure dry substances. When changing the dispersing material, check if the material of the rotary shaft seal and the O-rings is still suitable. It may be necessary to replace the parts against parts made of other materials. In case of doubt, please contact your supplier or the IKA -Werke directly. 12 magiclab 09/12

13 Important Important The machine is not suited for processing abrasive substances. Abrasive substances cause early wear particularly of the rotary shaft seal which may lead to undesired product leakage. For intended use, the magiclab must be installed on a stable, even, and non-slip laboratory table. Do not install it on wooden or synthetic tabletops. Wear personal protective equipment in accordance with the hazard category of the medium to be processed. Important magiclab 09/12 13

14 1.6 BASIC SAFETY INSTRUCTIONS DURING SERVICE AND MAINTENANCE Danger Danger Danger Danger due to electrical current! Before carrying out any maintenance or repair work switch off the mains switch of the power supply and unplug the mains plug. The voltage-carrying components inside the unit may continue be life for some time after the mains plug is pulled. Contact to these live components has serious effects on health and life. The machine may only be maintained by qualified and authorised persons observing the safety instructions and who are familiar with the operating instructions (also of the subassemblies) and who are able to follow these instructions! Before carrying out any maintenance or repair work block the access to the work area of the machine to unauthorised persons! Attach or erect a warn sign that draws the attention to the maintenance or repair work! Before carrying out any maintenance and repair work ensure that all parts of the machine that must possibly be touched have cooled down to ambient temperature! Hot surface Ensure proper disposal of environmentally hazardous lubricating, cooling or cleaning agents! Caution 14 magiclab 09/12

15 1.7 WORK ON THE ELECTRICAL EQUIPMENT Danger Repair work on the electrical equipment of the machine may only be carried out by a skilled electrician! Check the electrical equipment at regular intervals! Tighten loose connections again! Immediately replace damaged lines/cables! Only disconnect electrical plug connections when the machine is switched off! Always keep the control cabinet closed! Access only for author-ised persons with key/tool! Never clean control cabinets and other housings of the electrical equipment using a water hose! 1.8 OBSERVE THE ENVIRONMENTAL PROTECTION REGULATIONS Danger During any work at and with the machine the legal obligations concerning waste avoidance and proper recycling/disposal must be observed. Especially during installation, repair, and maintenance work substances being hazardous to water such as lubricating greases and oils coolants solvent-based cleaning liquids may not contaminate the soil or get into the sewage system! These substances must be stored, transported, and disposed in suitable containers! magiclab 09/12 15

16 1.9 OTHER DANGERS The machine has been designed in such a way that neither the machine itself nor its accessories may present any danger to persons, products or the environment. The operating instructions have been drawn up in such a way that no dangers should arise if the warnings and maintenance guidelines are observed. It is, however, impossible to rule out danger sources attributable to human error. No other risks are to be anticipated upon proper use of the machine and consideration of the recommendations and guidelines in accordance with the regulations governing the prevention of accidents and the employer's liability insurance associations. 16 magiclab 09/12

17 2. Specifications OPERATION AS BASIC UNTI WITH MODULE UTL Nominal rotor speed rpm Rotor speed range rpm Nominal torque 0.28 Nm (for a short interval max Nm) Dimensions (W x L x H) 170 mm x 270 mm x 215 mm Inlet socket Clamp ¾" AD25 / ID 15 Outlet socket Clamp ½" AD25 / ID 9 Double chamber connection hose Da 6 mm ±0.1 OPERATION AS DR Nominal rotor speed rpm Rotor speed range rpm Dimensions (W x L x H) 170mm x 270mm x 235mm Inlet socket Clamp ¾" Outlet socket Clamp ½" Double chamber connection hose Da 6 mm ±0.1 OPERATION AS DRS Nominal rotor speed Rotor speed range rpm rpm OPERATION AS MK Nominal rotor speed rpm Rotor speed rpm Dimensions (W x L x H) 170 mm x 270 mm x 225 mm Inlet socket Clamp ¾" Outlet socket Clamp ½" Double chamber connection hose Da 6 mm ±0.1 OPERATION AS MHD Nominal rotor speed rpm Rotor speed rpm Dimensions (W x L x H) 170 mm x 270 mm x 235 mm Inlet socket solid Di 25 mm / Da 35 mm Inlet socket liquid hose Da 6 mm ±0.1 Outlet socket Clamp ½" Double chamber connection hose Da 6 mm ±0.1 OPERATION AS CMS Nominal rotor speed rpm Rotor speed rpm Dimensions (W x L x H) 170 mm x 270 mm x 285 mm Inlet socket solid / liquid Clamp ¾" Inlet socket liquid Clamp ¾" Outlet socket Clamp ¾" Double chamber connection hose Da 6 mm ±0.1 OPERATION AS UTC Rotor speed Dimensions (W x L x H) rpm 170 mm x 270 mm x 420 mm magiclab 09/12 17

18 OTHER GENERAL DATA Product: Max. permissible product temperature continuous operation 80 C Max. permissible product temperature short time 120 C Max. permissible product operational overpressure 2.5 bar Max. permissible product vacuum with special rotary shaft seal ring Double chamber: Max. permissible temperature double chamber continuous operation 80 C -500 mbar Max. permissible temperature double chamber temperature short time 120 C Max. permissible operational overpressure double chamber 2 bar Sound pressure level basic unit 75 db(a) Permissible ambient temperature C Permissible humidity 5 80 % Permissible continuous operation up to 80 C 100 % Permissible short time rating at 120 C 30% -18 min / h Permissible duty cycle with module UTC 25% - 15 min / h Weight basic unit Weight controller Weight complete system in transport case Dimensions controller (W x L x H) Dimensions transport case (W x L x H) 6 kg 4.5 kg 20 kg 250 mm x 160 mm x 300 mm 290 mm x 410 mm x 440 mm MAX. THROUGHPUT These values are measured at a nominal rotor speed of rpm using water at 20 C Basic unit single stage - generator 2G approx. 150 l / h Basic unit single stage - generator 4M approx. 130 l / h Basic unit single stage - generator 6F approx. 115 l / h Basic unit single stage - generator 2P approx. 190 l / h Module DR three stages generator 2G / 4M / 6F Module MK Module MHD, total throughput Module CMS RECOMMENDED VOLUMETRIC RANGE UTC Module UTC with UTC-NK-18G Module UTC with UTC-NK-25G Module UTC with UTC-NK-25F approx. 80 l / h approx. 200 l / h approx. 60 l / h approx l / h l l l MATERIAL Product contacting parts stainless steel / Rotary shaft seal 1 PTFE Compound Rotary shaft seal 2 PTFE Compound Gamma sealing FPM Elastomere working chamber FPM Frame and motor aluminium lacquer Housing controller stainless steel / magiclab 09/12

19 2.1 ELECTRICAL DATA Nominal voltage V / PE Frequency Hz Power output 900 W Motor speed rpm Protection class basic version IP 42 Protection class controller IP 40 Protection class magiclab with UTC IP 40 Insulation class F EX-protection none Mains voltage Max. supply voltage fluctuation Mains frequency Fuse protection (to be provided by customer) V / PE ± 5% of mains voltage Hz 15 A Controller cable 2 m, connected ready for use: - Grounded plug - Type 203A-VII / 16A / 250V / VDE Europe - Type 404 BS/1363A / 13A / 250V UK - Type N6/15 / 15A / 250V / UL USA / Canada - Type 405-AS311 / 15A / 250V / SAA AUS - Type 23G / 16A / 250V / SEV CH - Type PRC/3/16 / 16A / 250V / CCC China - Grounded connector for rubber connector / C 19 / 16A / 250V / UL-CSA-VDE - Cable 3 x 1.5 mm² Contamination level 2 Overvoltage category II Protection class I CONNECTION CONDITIONS The machine may be connected to TN- and TT-type supply circuits. Connection to IT-type supply circuits is not allowed, since there is about twice the voltage strain in case of earth leakage, and limit values for air and crawling according to EN can no longer be observed. LEAKAGE CURRENT PROTECTION When using FI circuit breaker in the mains line only use selective AC/DC surge protectors which are suited for high frequency. ENVIRONMENTAL CONDITIONS Operation at terrestrial altitude max m TEMPERATURE MEASUREMENT Measurement range temperature C Accuracy temperature measurement ± 1 C TIMER-FUNCTION Time range Time steps 0 99 min 10 s magiclab 09/12 19

20 3. Unpacking The magiclab is assembled as module UTL and delivered in a transport box. The other modules are disassembled in the drawers of the box. Please unpack the machine and/or the dispersing tools carefully and inspect them for damage. It is important that any damage is detected as soon as the items are unpacked. A record of the relevant facts may be required (railway, mail or carrier). Remove the packing material of magiclab in the transport box (only the packing material behind the transport box door) before starting the machine, to avoid damage to the controller. The machine delivery range includes: basic unit with module UTL, the operating panel, the controller in the transport box, the tool set and the operating manual. Controller Transport box Operating unit Basic unit with module UTL Fig.: Delivery range magiclab with transport box, controller and operating unit 20 magiclab 09/12

21 4. Description Basic unit and modules Module UTL Operating panel Basic unit The basic unit of the magiclab is a single-stage, high-quality and multipurpose dispersion machine for continuous dispersion of liquids. The basic version can assembled with different dispersion modules. The drive unit is a highspeed dispersing and emulsifying unit capable of handling free-flowing and liquid media in continuous lines or in batches. A dispersion is the dissolution and diffusion of a solid, liquid or gaseous phase in a continuum that is not consolute with that phase. magiclab 09/12 21

22 4.1 MODULAR DESIGN The magiclab has a modular design. In its basic version, the magiclab will be delivered ready for connection. Outlet Inlet Double casing in- and outlet Fig. Module UTL Generator 4M Optionally, it can be converted into the following machine types using the modules listed below: Module DISPAX-REACTOR DR Three-stage dispersion machine Module MK Colloid mill Module MHD for mixing and dispersion of powdery substances in liquids Module CMS for mixing and dispersion of powdery substances in liquids Module UTC Extension stage for dispersion tools S 25-N The different modules are described in the separate chapters. To convert the machine from the basic unit with module UTL into one of the other modules only the product-contacting parts must be changed. 22 magiclab 09/12

23 4.2 ASSEMBLY INFORMATION ASSEMBLY TOOLS For assembly and disassembly it is recommended to use the tool set included in delivery range. Pos Items Ident no. Designation 10 1 T Tool bag 20 1 T Pliers S U Open end wrench OW 8/ U Open end wrench OW 11/ U Open end wrench OW U Open end wrench OW U Hexagon wrench OW 80 1 U Hexagon wrench OW U Lubricating grease magiclab 09/12 23

24 SAFETY NOTES Danger Warning Danger Inadverted starting of the machine has serious effect on health and life. Before changing the modules unplug the mains plug and secure the machine against inadverted starting! When pumps or similar components are integrated in the system make sure to provide protection against inadverted starting of the machine. After assembly works and before the drive is switched on, check the clearance of the machine's drive shaft by manually turning it. Turning the machine's drive shaft may have serious effects on health and life. When turning the shaft manually, protect the drive against inadvertent starting! Mounting screws on the clamps as well as on the stand shaft may come loose due to vibrations, this may lead to serious effect on health or life. For safety reasons check the mounting screws on the clamps and the stand shaft, if mounted. If necessary tighten the screws. During the assembly of the modules there is a danger of cutting on the sharp edged tools. Wear protective gloves. Caution In order to avoid damage to the machine during the assembly please observe the following instructions: Important Check the state of the of the rotary shaft seal and O-rings during assembly. Damage of the sealing is indicated by: medium flows under the sidewise clamps. decrease of pressure in a closed system. Pay attention to the mounting and positioning of the rotors. The keyways and keys have to be locked. Make sure that all O-rings are mounted before starting the machine. During assembly pay attention that the O-rings between the individual parts are inserted correctly in the groove when fitting parts together. Tighten the screws of the sidewise clamps at 5.9 Nm fastening torque. 24 magiclab 09/12

25 In order to make a later disassembly easier we recommend to slightly coat the hubs of rotors, distance sleeves, and O-rings with a suitable grease (e.g. Klübersynth UH by Fa. Klüber) before assembly. Note The numbering in the description is for better understanding of the spare part lists. If there is a number with "-basic, it is a part of the basic machine with module UTL. Note magiclab 09/12 25

26 4.3 BASIC UNIT MODULE UTL Clamp Intake Operating panel Double chamber inlet Module UTL generator 4M Double chamber outlet Outlet Basic unit FUNCTIONAL PRINCIPLE OF THE BASIC VERSION MODULE UTL The basic machine is a single-stage high-performance machine for continuous dispersion of liquids. Single-stage dispersing machines are also known at IKA under the trade name ULTRA-TURRAX INLINE or abbreviated UTL. Thus, the magiclab is especially suitable for scale-up purposes to larger production machines particularly of the Inline 2000 series. The dispersing action is based on the rotor-stator principle, which means that a high-speed rotor with very narrow slots rotates in a stator. This produces high shearing energies between rotor and stator. The system consisting of rotor and stator is also called generator. With the help of different fine-toothed generators the machine can be adapted to the respective dispersing task. The different generators must always be used in pairs. Rotors and stators with different fine-toothed generators must not be combined with one another, as this might damage the machine. The machine is not self-priming, however, it can build up a pressure at the outlet and thus overcome a certain lift. The lift depends on the tool used and the speed. 26 magiclab 09/12

27 A DC-brushless motor is used as the drive with a speed range of rpm. The drive shaft is the rotor shaft for the dispersion tools. The circumferential speed at the periphery of the rotor is 23 m/s on rpm and 40m/s on rpm. As the circumferential speed of the rotor has a decisive influence on the dispersion result, the magiclab controller with the operator panel offers an excellent possibility to adapt the machine to the processing requirements. With certain products or product characteristics, e.g. high viscosity or a combinations of fine generators, and at very high rotational speed, the motor might reach its performance limits. In this case the nominal torque of the motor should not be exceeded for a longer period. To avoid this effect the speed should be reduced until actual speed and nominal speed are almost the same. The two speed values are shown on the display of the magiclab operating panel. In case of an overload the motor is switched off by means of a thermal motor protection machine. GENERATORS 2G 4M 6F 2P magiclab 09/12 27

28 CONNECTIONS The machine has 2 connections for products lines. A vertical connection for the introduction of material is on the upper part of the machine. Inside the machine the components get mixed and homogenised. The connection for the product discharge is located in the pump chamber with a horizontal clamp. The module UTL can build up a pressure on the outlet side and thus overcome a certain lift. The lift depends on the tool used and the speed. DISASSEMBLY During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. The basic unit is delivered completely assembled. The numbers and descriptions below refer to the following drawings and spare part lists. The basic version can disassembled for cleaning and modification in this order: Loosen the product pipes. Loosen the screws of the both sidewise clamps (720-basic) and remove clamps. Lift up the inlet flange (704-basic). Lift up the stator with O-rings (906-basic, 608, 610). Loosen the pressure nut (730-basic) with an open end wrench OW 8 anticlockwise, the distance sleeve (731-basic) has got a spanner flat for a open-end wrench OW 11. Lift up the distance bush and the both rotor 0 (732-basic). Remove the rotor (904-basic). Remove the pumping chamber (710-basic). Machine version: Basic version without UTL. ASSEMBLY During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. Assembly is carried out in reverse order as described under "Disassembly. 28 magiclab 09/12

29 DRAWING Fig. Exploded view basic unit with module UTL magiclab 09/12 29

30 SPARE PART LIST OF BASIC UNIT WITH MODULE UTL Spare part list number U Pos Items Ident no. Designation U Drive U Housing complete U Sling disc U Axial face seal cartridge cpl U Distance sleeve for rotary shaft seal U Sealing flange complete U Sealing flange U Rotary shaft seal T Circlip S Screw DIN 6912 M4x10-A U Sealing set basic unit with module UTL U Pumping chamber U Clamping flange U Sealing disk U Connection for hose U Clamp, complete U Pressure nut U Distance sleeve U Rotor U Generator pack 4M U Rotor 4M * U Stator 4M * U Temperature sensor S Clampspannring DN ½"-3/4" S Clamp sealing DN ½" U Controller magiclab U Operating panel U Case until Controller serial no U Case as of Controller serial no U Case inlay U Case inlay U Assembling sleeve * Only available as generator pack! 30 magiclab 09/12

31 STANDARD PARE PART LIST SEALING SET FPM BASIC UNIT WITH MODULE UTL Spare part list number U Pos Items Ident no. Designation S O-ring FPM 8x1, U O-ring FPM 56.87x U O-ring FPM 37.82x U O-ring FPM 31.47x T O-Ring FPM 20,35x1, S O-ring FPM 28.3x S Clamp sealing FPM DN ½" SPARE PARTS LIST FOR OPTIONAL SEALING SET EPDM(FDA) BASIC UNIT WITH MODULE UTL Stücklistennummer U Pos Items Ident no. Designation S O-ring EPDM(FDA) 8x U O-ring EPDM(FDA) 56.87x U O-ring EPDM(FDA) 37.82x U O-ring EPDM(FDA) 31.47x T O-Ring EPDM(FDA) 20,35x1, T O-ring EPDM(FDA) 28.3x T Clamp sealing EPDM(FDA) DN ½ SPARE PARTS LIST FOR OPTIONAL SEALING SET FFPM BASIC UNIT WITH MODULE UTL Spare part list number U Pos Items Ident no. Designation U O-ring FFPM 8x U O-ring FFPM 56.87x U O-ring FFPM 37.82x U O-ring FFPM 31.47x T O-Ring FFPM 20,35x, T O-ring FFPM 28.3x U Clamp sealing Gylon blue DN ½ magiclab 09/12 31

32 4.4 MODULE DISPAX REACTOR DR 2 additional generators Inlet Outlet FUNCTIONAL PRINCIPLE OF MODULE DR The magiclab with the module DISPAX-REACTOR in contrast to the basic unit with module UTL is a three-stage dispersion machine with three generators being installed one after the other. This multistage arrangement of rotor-stator-systems makes it possible to answer maximum requirements on homogenisation and dispersion of emulsions and suspensions. W ith the help of different fine-toothed generators the machine can be adapted to the respective dispersing task. The generators can be combined in any order, but the coarser-toothed generators should be installed towards the inlet. The standard rotation speed of the module DR is rpm and rpm in case of the module DRS. This corresponds to the standard circumferential speeds of 23 m/s and 40 m/s, required for Up- Scaling to other machine sizes. The machine is not self-priming, however, it can build up a pressure at the outlet and thus overcome a certain lift. The lifting capacity depends on the tool used and the speed. The three-stage machine achieves a higher lift than the single-stage basic machine. With certain products or product characteristics, e.g. high viscosity or a combinations of fine generators, and at very high rotational speed, the motor might reach its performance limits. In this case the nominal torque of the motor should not be exceeded for a longer period. To avoid this effect the speed should be reduced until actual speed and nominal speed are almost the same. 32 magiclab 09/12

33 The two speed values are shown on the display of the magiclab operating panel. In case of an overload the motor is switched off by means of a thermal motor protection machine. CONNECTIONS The machine has the same connections for products lines as the basic unit. ASSEMBLY During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. The basic unit without module UTL is taken as basis for assembly (see page 28). The numbers and descriptions below refer to the following drawings and spare part lists. - Put the O-rings (608, 610) into the pumping chamber (710-basic). - Attach the pumping chamber (710-basic) carefully on the machine with the outlet flange pointing towards the front. - Put the rotor (1004) on the rotor shaft and turn it until the two keys engage. - Attach the stator (1006) with O-rings (608, 610) on the pumping chamber. - Put the rotor (904-basic) on the rotor shaft and turn it until the two keys engage. - Attach the stator (906-basic) with O-rings (608, 610) on the other stator. - Put the rotor (804) on the rotor shaft and turn it the two keys engage. - Put the distance sleeve (731-basic) on the rotor shaft. - Fit the pressure nut (730-basic) and tighten it with the open end wrench OW 8 clockwise. The distance bush has got spanner flats for counter. - Attach the stator (806) with O-rings (608, 610) on the other stator. - Attach the inlet flange (704-basic). - Put the both sidewise clamps (720-basic) on the machine and tighten the screws with the required fastening torque. DISASSEMBLY During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. Disassembly is carried out in reverse order as described under "Assembly. magiclab 09/12 33

34 DRAWING Fig. Exploded view basic unit with module DR 34 magiclab 09/12

35 SPARE PART LIST MODULE DR Spare part list number U Pos Items Ident no. Designation U Sealing set module DR U Generator pack 2G U Rotor 2G * U Stator 2G * U Generator pack 6F U Rotor 6F * U Stator 6F * * Only available as generator pack! SPARE PART LIST STANDARD SEALING SET FPM MODULE DR Spare part list number U Pos Items Ident no. Designation S O-ring FPM 8x U O-ring FPM 56.87x U O-ring FPM 37.82x U O-ring FPM 31.47x T O-Ring FPM 20,35x1, S O-ring FPM 28.3x S Clamp sealing FPM DN ½" SPARE PARTS LIST FOR OPTIONAL SEALING SET EPDM(FDA) MODULE DR Spare part list number U Pos Items Ident no. Designation S O-ring EPDM(FDA) 8x U O-ring EPDM(FDA) 56.87x U O-ring EPDM(FDA) 37.82x U O-ring EPDM(FDA) 31.47x T O-Ring EPDM(FDA) 20,35x1, T O-ring EPDM(FDA) 28.3x T Clamp sealing EPDM(FDA) DN ½ magiclab 09/12 35

36 SPARE PARTS LIST FOR OPTIONAL SEALING SET FFPM MODULE DR Spare part list number U Pos Items Ident no. Designation U O-ring FFPM 8x U O-ring FFPM 56.87x U O-ring FFPM 37.82x U O-ring FFPM 31.47x T O-Ring FFPM 20,35x, T O-ring FFPM 28.3x U Clamp sealing Gylon blue DN ½ 36 magiclab 09/12

37 4.5 MODULE COLLOID MILL MK Inlet Adjusting ring Locking screw Outlet FUNCTIONAL PRINCIPLE OF THE COLLOID MILL MK The magiclab with the module colloid mill MK is a high-performance colloid mill including a grinding gear, which, like the basic machine, is designed according to the rotor-statorprinciple. However, the grinding gear design differs considerably from that of the basic machine. The grinding gap between rotor and stator has a conical design and allows a continuous adjustment of the grinding gap by axially displacing the stator. This grinding gap adjustment enables an optimum adaptation of the machine for the production of stable emulsions and finest particles during wet milling. The grinding gap is adjusted manually using an adjusting ring on the outside of the housing. The grinding gear has a standard longitudinal toothing and is made of two parts, i.e. both the rotor and the stator consist of two stages in tandem arrangement with different fine toothings each. The first stage has a slightly coarser toothing and is provided with a special feed zone. The second stage has a very fine toothing. magiclab 09/12 37

38 The machine is not self-priming, however, it can build up a pressure at the outlet and thus overcome a certain lift. The lift depends on the adjusted grinding gap and the speed. Like the basic machine, the speed of the magiclab with the module colloid mill MK can be adjusted from 3000 rpm to rpm. Operation with the module colloid mill MK should first be started at the standard speed of rpm, and all further optimisations should be realised on the basis of this speed. With certain products or product characteristics, e.g. high viscosity or a combinations of fine generators, and at very high rotational speed, the motor might reach its performance limits. In this case the nominal torque of the motor should not be exceeded for a longer period. To avoid this effect the speed should be reduced until actual speed and nominal speed are almost the same. The two speed values are shown on the display of the magiclab operating panel. In case of an overload the motor is switched off by means of a thermal motor protection machine. CONNECTIONS The machine has got the same product line connections as the basic version. GRINDING GAP ADJUSTMENT Important In order to avoid damage to the tools the machine may only be switched on after the grinding gap adjustment. The module colloid mill MK can be adapted to the process using the continuous grinding gap adjustment. The grinding gap is adjusted manually by turning the adjusting ring being located on the outside of the housing. In dependence on the angle of rotation the grinding gap is obtained. The stator is fixed with a locking screw, which must locked after adjusting the grinding gap. Indicated angle [ ] Rotations of the adjusting ring Radial gap [mm] / / / / / Before starting the machine turn the adjusting ring clockwise until it reaches a tangible stop. The grinding gap is now set to zero, i.e. the rotor is now in contact with the stator. In this position, the machine must definitely not be switched on. Now, the running clearance must be adjusted. For adjusting the running clearance the adjusting ring is turned clockwise until the rotor only slightly brushes against the stator. This can be checked with the tubular box spanner (OW8) 38 magiclab 09/12

39 which is placed on the pressing nut and is turned clockwise. In order to obtain the desired basic clearance (0 position) or radial gap adjustment, the adjusting ring must be turned anticlockwise by 180. Now, a safe running clearance between rotor and stator is set. Fix the set screw to secure the adjusting ring. ASSEMBLY During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. The basic unit without module UTL is taken as basis for assembly (see page 28). The numbers and descriptions below refer to the following drawings and spare part lists. - Put the rotor MK (904) on the rotor shaft and adjust the keyway - Put the distance sleeve MK (731) on the rotor shaft and adjust the keyway - Fit the pressure nut (730-basic) and tighten it with the tubular box spanner OW 8 clockwise. The bush MK has got spanner flats for countering. - Attach the complete stator unit (900) - Put the both sidewise clamps (720-basic) on the machine and tighten the screws with the required fastening torque. - Adjust the grinding gap. DISASSEMBLY During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. Disassembly is carried out in reverse order as described under "Assembly. magiclab 09/12 39

40 DRAWING Fig. Exploded view basic unit with module MK 40 magiclab 09/12

41 DISASSEMBLY During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. - Loosen the locking screw (735, 736) - Turn the adjusting ring (716) with the stator (902) clockwise completely out of the pumping chamber (710). The inlet flange (704) is lifted up, too. - Remove the Inlet flange (704) carefully from the adjusting ring unit. ASSEMBLY THE STATOR UNIT During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. Coat the thread of the adjusting ring unit with a suitable grease. - Position the cylindrical bolt centrically into the slot of the pumping chamber. Put on the inlet flange carefully and take care, that the cylindrical bolt fits into the respective bore and the inlet socket is fixed in the slot. The stator unit (900) is delivered completely mounted. DRAWING Fig. Drawing generator unit magiclab 09/12 41

42 CHANGING THE O-RING (611) During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. Loosen screws of stator (40) Loosen lower stator part from the upper stator part with a soft-face hammer by beating on bolt (722). Replace O-ring (611). Adjust bolt (722) with the soft-face hammer to its original position. Push upper stator part carefully onto lower stator part observing the markings at the outer rings (on bolt (722)) and mounting the adjusting ring. Insert and tighten screws (40). DRAWING Fig. Drawing stator unit 42 magiclab 09/12

43 SPARE PART LIST MODULE MK Spare part list number U Pos Items Ident no. Designation U Sealing set MODULE MK U Inlet flange DN ¾" MK U Pumping chamber MK U Adjusting ring U Bolt U Sleeve MK U Knurled nut U Threaded pin U Stator unit* U Rotor MK * Only available as stator unit SPARE PARTS LIST STATOR UNIT SPARE PART LIST NUMBER U Pos Items Ident no. Designation U O-ring FPM(FDA) 31x U Adjusting ring U Bolt U Stator MK SPARE PART LIST MODULE MKO SPARE PART LIST NUMBER U Pos Items Ident no. Designation U O-ring FPM(FDA) 23,52x1, U O-ring FPM(FDA) 31x U O-ring FPM (FDA) 36.17x2, U Inlet flange DN 3/4" MAGICLAB U Pumping chamber MK clamp 1/2" U Adjusting ring Rg U Bolt DIN 7 4m6x14-A U Sleeve MK U Knurled nut DIN467-M4-NI U Threaded pin GN913.5-M4-12-KU U Stator unit MKO* U Rotor MKO * Only available as stator unit SPARE PARTS LIST STATOR UNIT SPARE PART LIST NUMBER U Pos Items Ident no. Designation U O-ring FPM(FDA) 31x U Adjusting ring U Bolt U Stator MKO magiclab 09/12 43

44 SPARE PART LIST STANDARD SEALING SET FPM MODULE MK/MKO Spare part list number U Pos Items Ident no. Designation S O-ring FPM 8x U O-ring FPM 56.87x U O-ring FPM 23.52x U O-ring FPM 31x U O-ring FPM 31.47x T O-Ring FPM 20,35x1, U O-ring FPM 36.17x S O-ring FPM 28.3x S Clamp sealing FPM DN ½" SPARE PARTS LIST FOR OPTIONAL SEALING SET EPDM(FDA) MODULE MK/MKO Spare part list number U Pos Items Ident no. Designation S O-ring EPDM(FDA) 8x U O-ring EPDM(FDA) 56.87x U O-ring EPDM(FDA) 23.52x U O-ring EPDM(FDA) 31x U O-ring EPDM(FDA) 31.47x T O-Ring EPDM(FDA) 20,35x1, U O-ring EPDM(FDA) 36.17x T O-ring EPDM(FDA) 28.3x T Clamp sealing EPDM(FDA) DN ½ SPARE PARTS LIST FOR OPTIONAL SEALING SET FFPM MODULE MK/MKO Spare part list number U Pos Items Ident no. Designation U O-ring FFPM 8x U O-ring FFPM 56.87x U O-ring FFPM 23.52x U O-ring FFPM 31x U O-ring FFPM 31.47x T O-Ring FFPM 20,35x1, U O-ring FFPM 36.17x T O-ring FFPM 28.3x U Clamp sealing Gylon blue DN ½ 44 magiclab 09/12

45 4.6 MODULE MHD Powder inlet Double chamber outlet Liquids inlet Outlet Double chamber inllet FUNCTIONAL PRINCIPLE OF MODULE MHD The magiclab with the module MHD is a high-quality, multipurpose mixing machine for continuous mixing of solid substances with liquids. Both the solid and the liquid component must be proportioned into the machine at the respective inlet socket. In the machine itself, the components are intensively mixed, dispersed or homogenised and are discharged from the machine via an outlet socket. The controlled feeding of the liquid and the solid component results in a final product with proportional quantities, the exactness depending on the feeding devices. Feeding can be realised using e.g. the following devices: Proportioning of the solid component Proportioning of the liquid component Dosing device Volumetric proportioning screw Gravimetric ratio weigher Hose pump Gear pump Remark Reduced expenditure, varying proportioning accuracy High expenditure, high proportioning accuracy Simple, not suitable for all products High expenditure, suitable for most products magiclab 09/12 45

46 The module MHD can build up a pressure on the outlet side and thus overcome a certain lift. The lift depends on the tool used and the speed. Powder inlet Double chamber outlet Outlet Liquids inlet Double chamber inlet Fig. Module MHD The speed of the magiclab with the module MHD can be adjusted from 3000 rpm to rpm. Operation with the module MHD should first be started at the standard speed of rpm, and all further optimisations should be realised on the basis of this speed. With certain products or product characteristics, e.g. high viscosity or a combinations of fine generators, and at very high rotational speed, the motor might reach its performance limits. In this case the nominal torque of the motor should not be exceeded for a longer period. To avoid this effect the speed should be reduced until actual speed and nominal speed are almost the same. The two speed values are shown on the display of the magiclab operating panel. In case of an overload the motor is switched off by means of a thermal motor protection device. MIXING TOOLS The mixing tools of the machine are located above the rotary shaft seal on the drive shaft. All the tools can be dismounted individually and thus an optimum adaptation to the set process goal is possible. Their task is to bring the fed mixing components in contact with each other, to mix them intensively and to discharge the mixed product from the machine. Depending on the mixing zone the tools have different functions. They are mounted on the drive shaft one after the other and are fixed by the topmost tool. This topmost tool is designed as a screw. The screw is located in the area of the solids inlet and has the following tasks: Take the solid substance in the premixing chamber. Clear the solids inlet area from possible caking. Cut the "wet" premixing area off of the "dry" solids area. 46 magiclab 09/12

47 The tools of the premixing area are located below the screw. In this zone, the solid and the liquid component get in touch with each other. With their high speeds the tools cause a strong turbulence and thus the mixing of the substances as well as a transport into the next chamber downwards. The lowest chamber houses a centrifugal impeller. This is designed as a pump wheel and the outcome together with stator 2G is a additional dispersion stage. PREMIXING CHAMBER In the premixing chamber, the components to be mixed get in touch with each other. It consists of a casing with a central liquid connection and an exchangeable injector jacket. It is fixed by the solids inlet socket. The liquid component is fed into the central connection under pressure, distributes in the space between casing and injector jacket and will then be injected into the premixing area via the openings of the injector jacket. PUMP HOUSING The pump housing is located below the premixing chamber. A stator and thus an additional dispersion stage is installed here. The product to be mixed is radially accelerated by the rotating impeller and discharged via the outlet socket. CONNECTIONS The machine has three connections for product pipes. In case of the module MHD, both the solid and the liquid component must be proportioned into the machine at the respective inlet socket. In the machine itself, the components are mixed or homogenised and discharged from the machine via an outlet socket. The controlled feeding of the liquid and the solid component results in a final product with proportional quantities, the exactness depending on the feeding devices. The vertical connecting sleeve for the solids supply is located in the upper section of the machine. The connection of a volumetric or gravimetric proportioning screw must be realised. The central connection for the liquid mixing component supply is located in the casing. The connection is situated at the side of the casing. Here, the delivery line of a delivery pump or a proportioning unit for the liquid must be provided. W hen installing pipework, observe the items mentioned under "Connection on the suction side". The connection for the product discharge is located in the pump housing. The MHD module can build up a pressure on the outlet side and thus overcome a certain lift. The lift depends on the tool used and the speed. When installing pipework, observe the items mentioned under "Connection on the delivery side". magiclab 09/12 47

48 ASSEMBLY During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. The basic unit without module UTL is taken as basis for assembly (see page 28). The numbers and descriptions below refer to the following drawings and spare part lists. Put the O-rings (608, 610) into the pumping chamber (710-basic). Place the pumping chamber (710-basic) carefully on the machine with the outlet flange to the front. Put the pump rotor (1004) on the rotor shaft and turn it until the two keys engage. Attach the stator (1006) with O-rings (608, 610) on the pumping chamber. Put the mixing tools (804) with 180 offset to each other on the rotor shaft and turn it until the two keys engage. The 180 offset is important for process reliability. Put the distance sleeve (731-basic) on the rotor shaft. Screw on the feeding worm (802) and tighten it clockwise using the open-end wrench OW10 and tubular box (OW8) spanner. The distance bush is provided with spanner flats for countering with a open wrench OW11. Attach the housing (708) with O-rings (608, 610) on the stator. Place injector chamber (902) with O-ring (615) in the housing (708). Attach the inlet flange with PTFE-inlet (704, 705) and adjust the clamp slots. Put the both sidewise clamps (720-basic) on the machine and tighten the screws with the required fastening torque. DISASSEMBLY During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. Disassembly is carried out in reverse order as described under "Assembly. 48 magiclab 09/12

49 DRAWING Fig. Exploded view basic unit with module MHD magiclab 09/12 49

50 SPARE PART LIST MODULE MHD Spare part list number U Pos Items Ident no. Designation U Sealing set MODULE MHD U Inlet flange DN U PTFE-insert U Double chamber housing U Connection for hose U Feeding worm U Mixing tool U Injector chamber U Generator pack 2P U Pumping wheel P* U Stator 2G* * Only available as generator pack! SPARE PART LIST STANDARD SEALING SET FPM MODULE MHD Spare part list number U Pos Items Ident no. Designation S O-ring FPM 8x U O-ring FPM 56.87x U O-ring FPM 37.82x U O-ring FPM 31.47x T O-Ring FPM 20,35x1, U O-ring FPM(FDA) 31x S O-ring FPM 28.3x S Clamp sealing FPM DN ½" SPARE PARTS LIST FOR OPTIONAL SEALING SET EPDM(FDA) MODULE MHD Spare part list number U Pos Items Ident no. Designation S O-ring EPDM(FDA) 8x U O-ring EPDM(FDA) 56.87x U O-ring EPDM(FDA) 37.82x U O-ring EPDM(FDA) 31.47x T O-Ring EPDM(FDA) 20,35x1, U O-ring EPDM(FDA) 31x T O-ring EPDM(FDA) 28.3x T Clamp sealing EPDM(FDA) DN ½ 50 magiclab 09/12

51 SPARE PARTS LIST FOR OPTIONAL SEALING SET FFPM MODULE MHD Spare part list number U Pos Items Ident no. Designation U O-ring FFPM 8x U O-ring FFPM 56.87x U O-ring FFPM 37.82x U O-ring FFPM 31.47x T O-Ring FFPM 20,35x1, U O-ring FFPM 31x T O-ring FFPM 28.3x U Clamp sealing Gylon blue DN ½ magiclab 09/12 51

52 4.7 MODULE CMS Powder inlet Liquids inlet Outlet FUNCTIONAL PRINCIPLE OF MODULE CMS The magiclab with the module CMS is a high-quality multipurpose mixing machine for continuous mixing particularly of solid substances and liquids. The components are fed into the machine at different inlet sockets, are intensively mixed in the machine, homogenised, and discharged from the machine via an outlet socket. The machine is not self-priming the liquid feed. Therefore, a minimum admission pressure of approx bar at the liquid inlet must always be applied. The speed of the magiclab with the module CMS can be adjusted from 3000 rpm to rpm, however, the machine should be run at the standard speed of rpm. In case of certain products or product characteristics, e.g. high viscosity, especially the power limit of the machine can be reached at very high speeds. The given speed could not reached. In case of an overload of the motor, it will be switched off by activating a thermal motor protection. 52 magiclab 09/12

53 CONNECTIONS The machine has three connections for product pipes. The inlet housing with the vertical inlet flange for solids suction is located in the upper section of the machine. The horizontal connection for the liquid component is located below it. The product discharge connection and the cleaning connection are located horizontally at the bottom of the pump housing. Pay attention on the following instructions for working with CMS: To achieve optimum performance of the CMS, the connecting pipes to the container should be laid as short and as direct as possible. Do not reduce the pipework preceding and following the CMS, do not install any filters or other equipment inhibiting the flow. Avoid the installation of elbows and other equipment causing pressure losses. For viscosity > 500 mpas, increase the cross-sections, if necessary. Exclusively use shut-off valves with free passage (no flap valves or the like). Lay all pipework with a downward slope toward the CMS. Avoid bubbles in the pipework. When using hoses, these must be suitable for vacuums. When using foaming products, the return to the container should be below level. Preferably use fixed pipework, as high impulses may occur due to the high throughput ASSEMBLY During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. Important The machine may not be operated (even for short periods) without an intact sealing circuit. Otherwise the rotary shaft seal (810) may be destroyed. Check if all O-rings are attached before assembly The basic unit without module UTL is taken as assembly (see page 28). The numbers and descriptions below refer to the following drawings and spare part lists. - Remove the sealing flange (500-basic) carefully, to avoid damage to the sealing. Disassembly as described in chapter "8.1 Shaft seal. - Put the distance sleeve (415) for sealing ring on the rotor shaft and turn it until the two keys engage. - Put the O-rings (608, 610, 612, 613) into the sealing flange CMS (500). - Put the mounting sleeve for the sealing (7010-basic) on the rotor shaft. - Attach the sealing flange (500) and adjust the clamp slots. - Remove the mounting sleeve from the rotor shaft. - Put the generator (800) on the rotor shaft and tighten it with the pressure nut CMS (730) and the special tool. Make sure that the O-rings are in the generator and the shaft sealing is not damaged. - Attach the pumping chamber CMS (710) carefully on the machine with the outlet to the front side. - Attach the inlet flange with mounted inlet tube (704, 708) and adjust the clamp slots. - Disassemble the sidewise clamps and replace the bottom piece of the sidewise clamp with the bottom piece sidewise clamp CMS (1100). magiclab 09/12 53

54 - Put the both sidewise clamps (720) on the machine and tighten the screws with the required fastening torque. DISASSEMBLY During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. Disassembly is carried out in reverse order as described under "Assembly. Please observe that the clamps are mounted in their original state with the lower part of the base version, since they are only suited for the module CMS in this configuration. When using accessories for operation using circulation processes, with vacuum and pressure, or using other components, please observe the special operating instructions "magiclab Plant Accessories". Note 54 magiclab 09/12

55 DRAWING magiclab 09/12 55

56 Fig. Exploded view basic unit with module CMS 56 magiclab 09/12

57 DISASSEMBLING / ASSEMBLING THE GENERATOR It is only necessary to disassemble the generator during exchange of the rotary shaft seal in the generator. Loosen cylindrical screw (808). Remove the rotary shaft seal (810) from the upper rotor (804) using the enclosed disassembly tool and a hammer. Carefully press new rotary shaft seal in with a press, sealing lip inwards. Fix discharge rotor (806) with cylindrical screw (808) to upper rotor (804). Grease sealing lip of rotary shaft seal with the grease enclosed in the assembling set (see chapter 8.1) Carefully push generator on the tube in the inlet housing and turn it repeatedly in both directions adjusting the sealing lip to the tube. The generator is ready for operation magiclab 09/12 57

58 DRAWING Fig. Generator CMS 58 magiclab 09/12

59 SPARE PART LIST MODULE CMS Spare part list number U Pos Items Ident no. Designation U Distance sleeve U Sealing flange cpl. CMS U Sealing flange CMS U Rotary shaft seal T Circlip U Sealing set MODULE CMS U Inlet flange Clamp ¾" U Inlet housing Clamp ¾" U Pumping chamber CMS U Clamping flange U Sealing disk U Connection for hose U Pressure nut U Generator pack CMS U Rotor solid/liquid * U Screw DIN 84-M2.5x25 * U Rotor, outlet * U Rotary shaft seal U Bottom part clamp CMS U Disassembly tool WeDi CMS * Only available as generator pack! SPARE PART LIST STANDARD SEALING SET FPM MODULE CMS Spare part list number U Pos Items Ident no. Designation S O-ring FPM 8x U O-ring FPM 56.87x U O-ring FPM 37.82x S O-ring FPM 32x T O-Ring FPM 20,35x1, S O-ring FPM 28.3x T O-ring FPM 10x S O-ring FPM 18x1.5 magiclab 09/12 59

60 SPARE PARTS LIST FOR OPTIONAL SEALING SET EPDM(FDA) MODULE CMS Spare part list number U Pos Items Ident no. Designation S O-ring EPDM(FDA) 8x U O-ring EPDM(FDA) 56.87x U O-ring EPDM(FDA) 37.82x S O-ring EPDM(FDA) 32x T O-Ring EPDM(FDA) 20,35x1, T O-ring EPDM(FDA) 28.3x T O-ring EPDM(FDA) 10x T O-ring EPDM(FDA) 18x1.5 SPARE PARTS LIST FOR OPTIONAL SEALING SET FFPM MODULE CMS Spare part list number U Pos Items Ident no. Designation U O-ring FFPM 8x U O-ring FFPM 56.87x U O-ring FFPM 37.82x U O-ring FFPM 32x U O-ring FFPM 31.47x T O-ring FFPM 28.3x T O-ring FFPM 10x S O-ring FFPM 18x magiclab 09/12

61 4.8 MODULE UTC FUNCTIONAL PRINCIPLE OF MODULE UTC The magiclab with the module UTC is a dispersion machine for continuous dispersion of liquids. This module has to be operated on a laboratory stand with the shaft downwards. The following UTL dispersion tools can combined with the magiclab : UTC-NK-18 G / UTC-NK-25 G / UTC-NK-25 F Due to the high rotation speed of the rotor, the medium to be processed is automatically drawn axially into the dispersion head and then forced radially though the slots in the rotor/stator arrangement. The high accelerations acting on the material produce extremely strong shear and thrust forces. In addition, high turbulence occurs in the shear gap between rotor and stator, which provides optimum mixing of the suspension. The speed of the magiclab with the module UTC can be adjusted from 3000 rpm to rpm. Operation with the module UTC should first be started at the standard speed of rpm, and all further optimisations should be realised on the basis of this speed. The optimum speed is rpm. This corresponds to a circumferential speed of m/s. A processing time of a few minutes is usually sufficient to produce the desired fineness. Long processing times bring only insignificant improvements in the obtainable fineness; the energy expended serves merely to increase the temperature of the medium. magiclab 09/12 61

62 CONNECTIONS The magiclab with module UTC can be combined with IKA -dispersing tools of the series UTC-NK. ADDITIONAL SAFETY INSTRUCTIONS MODULE UTC Mounting screws on the flange of the drive unit may come loose due to vibrations, this may lead to serious effect on health or life. For safety reasons check the mounting screws on the flange of the drive unit. If necessary, tighten the screws. Danger Mounting screws on the clamps as well as on the stand shaft may come loose due to vibrations, this may lead to serious effect on health or life. For safety reasons check the mounting screws on the clamps and the stand shaft. If necessary, tighten the screws. Danger Warning Warning Unstable mounting of the module UTC may lead to serious effect on health or life. In order to increase the mechanical stability the drive unit should be mounted as close as possible to the stand shaft. When starting the machine there is a risk of spouting medium out of the container this may lead to serious effect on health or life. Switch on the drive only at the lowest speed setting. Then gradually increase the speed to the desired level. Make sure that no liquid enters into the drive unit, otherwise there is a risk of damage to the machine. Important Important During operation it is possible that the processed medium abrais impurified by abrsives of the machine or of the rotating accessory parts. The dispersion tool is not suited for continous operation. Important 62 magiclab 09/12

63 Important Never run dispersion tools dry, as the gasket and bearings will be destroyed if the tools are not cooled by the medium. The gasket and bearings are made of PTFE and stainless steel; the following points should therefore be noted: Chemical reactions of PTFE occur in contact with molten or solute alkali metals and alkaline earth metals, as well as with fine powders of metals in group 2 and 3 of the periodic system at temperature above 300 C-400 C. Only elementary fluorine, chlorotrifluoride and alkali metals attack it; halogenated hydrocarbons have a reversible swelling effect. (Source: Römpps Chemie-Lexikon und "Ulmann" Band 19) Only dispersion and agitating tools approved by IKA may be used! Otherwise the warranty and the declaration of conformity will become void! Note The optimum speed and disperson time has to be defined via tests. Note magiclab 09/12 63

64 ASSEMBLY MODULE UTC During assembly and disassembly the safety instructions given in chapter 1, chapter 4.2 and under "Additional safety instructions module UTC must be observed. The basic unit without module UTL is taken as basis for assembly (see page 28). The numbers and descriptions below refer to the following drawings and spare part lists. For mounting the module UTC position the machine on ist feet. Carefully dismouting sealing flange (500-basic), to avoid damage to the rotary seal. ssee chapter 8 Maintenance Shaft seal. Dismount thrower disk (406). Push intermediate flange (730) as mounted unit onto the drive shaft and turn distance sleeve (735), until the two teeth engage. Screw down the sealing flange with the two screws of the sealing flange. Push coupling onto drive shaft by turning it, holding the distance sleeve with fork wrench SW11. Place flange for dispersion tool (901) onto intermediate flange and position grip screw. Insert clamps (720-basic) into the provided openings and thighten both screws with the defined torque. Mounting on shaft stand see Assembly shaft stand. Machine is mounted on the corresponding stand by means of a IKA -cross sleeve R271. Mounting of IKA -dispersion tools UTC-NK-18G, UTC-NK-25G or UTC-NK-25F see Assembly of disperion tool. DISASSEMBLY MODULE UTC During assembly and disassembly the safety instructions given in chapter 1, chapter 4.2 and under "Additional safety instructions module UTC must be observed. Disassembly is carried out in reverse order as described under "Assembly. ASSEMBLY STAND SHAFT During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. - Loosen the mounting screw of the operation panel at the backside with Allen key OW10 - Screw the stand shaft with counter nut (1102, 1004) to the rear side. - Adjust the fastener of the operation panel in the required position. - Tighten the stand shaft with the open-end wrench OW13 and OW18. DISASSEMBLY STAND SHAFT During assembly and disassembly the safety instructions given in chapter 1 and chapter 4.2 must be observed. Disassembly is carried out in reverse order as described under "Assembly. 64 magiclab 09/12

65 DRAWING Fig. Basic unit with module UTC Fig. 3D-view of basic unit with modulea UTC magiclab 09/12 65

66 ASSEMBLY DISPERSION TOOL IN UTC CONNECTION During assembly and disassembly the safety instructions given in chapter 1, chapter 4.2 and under "Additional safety instructions module UTC must be observed. Insert dispersion tool into the UTC connection until it stops. Make sure the tool is arrested on the pin (906) Tighten hand screw (903). The distance between the dispersion tool and the container bottom should not be less than 10mm. The filling level of the medium may not be less than about 55mm. If these conditions are met, the unit is ready for service when the mains plug has been plugged in. If this is not the case, safe operation cannot be guaranteed and the unit may be damaged. The entire unit may also be arranged somewhat off centre in order to avoid any undesired air admission caused by the strong rotational turbulence. DISASSEMBLY DISPERSION TOOL FROM UTC-CONNECTION During assembly and disassembly the safety instructions given in chapter 1, chapter 4.2 and under "Additional safety instructions module UTC must be observed. Disassembly is carried out in reverse order as described under "Assembly. DISPERSION TOOL Dispersion tools consist of shaft and generator. The shaft consists of shaft tube, shaft, shaft bearing and shaft sealing. The shaft alone is not suited for operation. For processing medium a combination of shaft plus generator is required. The shaft beyring is a combination of ball and friction type bearing, made of FTFE. The generator consists of rotor and stator. These parts can be removed form the shaft. Make sure to use the correct rotor-stator-combination. Never interchange different rotorstator combinations. There are three different dispersion heads for all kinds of processing tasks. UTC-NK-18G / UTC-NK-25G / UTC-NK-25F DISASSEMBLY DIPSERSION TOOLS UTC-NK The dispersion tool can be disassembled for cleaning as described below. Unscrew the rotor (60) from the shaft (20) using the generator and shaft key (7002, 7003) included in the UTC-connection package. The rotor is held fast by means of the generator key and screwed off from above by turning the shaft using the shaft key Unscrew the stator (70) from the shaft (10) left-hand-thread. Insert flat key into the front-end slot of the shaft tube. By using the generator key the stator may now be screwed off in a clockwise direction Pull the shaft (20) out of the shaft tube in a downward direction. The individual parts threaded on the shaft (30, 40, 50) may simply be pulled off In the case of wear replace the slotted bearing (50). 66 magiclab 09/12

67 ASSEMBLY DIPSERSION TOOLS UTC-NK Assembly is carried out in reverse order as described under "Assembly. When assembly ensure that the bearing bushing and the rotor are correctly installed. DRAWING DISPERAION TOOL UTC-NK magiclab 09/12 67

68 SPARE PART LIST DISPERSING TOOL S 25 N Parts list number U Pos items Ident number Designation U intermediate flange U ball bearing T circuit clip U spring wave S O-Ring FPM 28x U distance sleeve U flange for dispersion tool U spring catch U hand screw U coupling U pin U Stand shaft S Counter nut DIN 934 M12-A U Flat key U Shaft key U Generator key SPARE PARTS LIST DISPERSION TOOL UTC-NK Parts list number U Pos items Ident number Designation 10 1 U Shaft tube 20 1 U Rotor shaft 30 1 U Friction ring 40 1 U Sleeve 50 1 U Slotted ring bearing 60 1 U Rotor 18G 70 1 U Stator 18G SPARE PARTS LIST OPTION ROTOR / STATOR Identnummer U U U U Bezeichnung Rotor 25G Stator 25G Rotor 25F Stator 25F 68 magiclab 09/12

69 5. Brief test The following conditions have to be fulfilled before the machine is switched on: Check that the voltage on the designation plate matches the mains voltage. The socket to which the machine is connected must be fused with 15A. After installation of the machine on a safe ground, the machine can be electrically connected. For this, the machine plugs are plugged into the two suitable socket outlets of the controller. The controller must be connected by the enclosed connector cable to an adequate socket. The ambient conditions listed under "Technical specifications are fulfilled. Before starting the machine make sure the safety notes in chapter 6 "Working with the machine" are observed. When operating with a dispersion tool UTC NK the magiclab must be mounted on a stand suited for the weight. magiclab 09/12 69

70 6. Working with the machine The following should be checked during a brief test run: - Direction of rotation of the motor - counterclockwise - Unusual, mechanical noise Never reach into the mixing chamber. There is a risk of injury due to rotating mixing tools. Caution Important In order to avoid damage to the machine during the assembly please observe the following instructions: Check the state of the of the rotary shaft seal and O-rings during assembly. Damage of the sealing is indicated by: medium flows out under the sidewise clamps. decrease of pressure in a closed system. Pay attention to the mounting and positioning of the rotors. The keyways and keys have to be locked. Make sure that all O-rings are mounted before starting the machine. During assembly pay attention that the O-rings between the individual parts are inserted correctly in the groove when fitting parts together. Tighten the screws of the sidewise clamps at 5.9 Nm fastening torque. The machine may only run dry for a short period, otherwise the rotary shaft seal on the product side will be destroyed. Important The machine with module MK may only be switched on after radial gap adjustment. Otherwise there is a risk of damaging the machine. 70 magiclab 09/12

71 Note With certain products or product characteristics, e.g. high viscosity or a combinations of fine generators, and at very high rotational speed, the motor might reach its performance limits. In this case the nominal torque of the motor should not be exceeded for a longer period. To avoid this effect the speed should be reduced until actual speed and nominal speed are almost the same. The two speed values are shown on the display of the magiclab operating panel. In case of an overload the motor is switched off by means of a thermal motor protection device. Also observe the safety instructions in chapter 1. magiclab 09/12 71

72 6.1 INFORMATION ON WORKING WITH PRODUCT The magiclab has been particularly designed for processing liquids. With the MHD and CMS module, the magiclab can also mix powdery solids with liquids and homogenise them. However, for successful operation with the machine, the following must be observed: GENERAL The magiclab can be adapted to the application in question by means of individually exchangeable mixing tools. However, attention has to be paid that generally the possible throughput rates and lifts decrease with the use of finer tools. PERIPHERY The magiclab is not self-priming, however, it can build up a pressure at the outlet and thus overcome a certain lift. The lift depends on the tool used and the speed. In case of the MK module, the lift also depends on the adjusted grinding gap. A precondition for proper function and constant mixing performance is that the product to be mixed is supplied evenly e.g. via the optional feeding hopper (does not apply to the module MHD). Viscous product to be mixed, which does not flow independently into the machine via a hopper, may require to be fed into the magiclab using a pump. To feed the liquid component or to circulate the product to be mixed, pumps working according to the displacement principle, such as rotary piston, gear or eccentric screw pumps, proved successful. They have a relatively stable characteristic and are generally driven by variable speed geared motors. When using a pump, pay attention that the permissible operating pressure of 2.5 bar is not exceeded. 72 magiclab 09/12

73 6.2 OPERATION USING FLOW-THROUGH PROCESSES Inlet Outlet The product supply and discharge lines can be connected to inlet and outlet clamp flanges. Make sure that the clamp connection is tightened securely. Only use gasket and hose material which is compatible with the product and show a sufficient pressure, temperature and media resistance. magiclab 09/12 73

74 6.3 ACCESSORIES FOR CIRCULATION PROCESSES MICROPLANT Circulation pipe Funnel 3-way ball valve Hose connection Temperature sensor The accessories, which can be delivered by the IKA, can be mounted to the magiclab according to the dimension drawing. The plant should be secured on a stand because of better stability. Pay attention for the position of circulation pipe. It has to be installed min. 30mm in the vessel to avoid spouting of medium. SPARE PART LIST MICRO-PLANT Pos Items Ident no. Designation 10 1 U Vessel 1 liter 60 4 S Clamp ring DN ½ ¾ 80 1 U way ball valve 90 1 U Clamp hose nozzle Ø U Circulation pipe U Sealing set MicroPlant FPM SPARE PART LIST STANDARD SEALING SET FPM MICRO-PLANT FPM Spare part list U Pos Items Ident no. Designation 50 1 S Clamp sealing DN ¾, FPM S Clamp sealing DN ½, FPM 74 magiclab 09/12

75 SPARE PARTS LIST FOR OPTIONAL SEALING SET EPDM(FDA) MICRO-PLANT Spare part list number U Pos Items Ident no. Designation 50 1 S Clamp sealing DN ¾. EPDM(FDA) T Clamp sealing DN ½. EPDM(FDA) SPARE PARTS LIST FOR OPTIONAL SEALING SET GYLON BLUE (FFPM) MICRO-PLANT Spare part list number U Pos Items Ident no. Designation 50 1 U Clamp sealing DN ¾. Gylon blue U Clamp sealing DN ½. Gylon blue Please observe the special operating instructions "magiclab Plant Accessories" for further MicroPlant versions. Note magiclab 09/12 75

76 DRAWING Fig. Dimension sheet MicroPlant 76 magiclab 09/12

77 6.4 CONNECTOR DESIGN CONNECTION OF THE CUSTOMER If the accessories provided by the IKA are not used or the machine is permanently piped, pay attention that the pipework does not exert any additional load on the machine. CONNECTION ON THE SUCTION SIDE The following items have to be observed: The suction side should be designed as a free inlet if possible. The piping should be as short as possible and fitted with few elbows. Provide suitable supports and flexible connections in order to keep the machine free of loads exerted by the pipework. If the suction side is not designed as a free inlet, provide a prefilling unit. Carefully realise the connections on the suction side and avoid leakage. Avoid unfavourable conditions on the suction side, e.g. long piping, high suction height etc. Absolutely avoid any inclusion of air. The supply line must be laid rising towards the machine, and falling in case of inlet. Do not dimension the suction pipe smaller than the suction connection. Optimum conditions Unsuitable conditions Inclusion of air Inclusion of air CONNECTION ON THE DELIVERY SIDE The following items have to be observed: Keep the machine free of loads exerted by the pipework. Provide suitable supports and flexible connections for this. If the pipework is too long, the resistance of the pipework increases and the performance data of the machine change. The pipework diameter should be selected considering the resistance of the pipework. To be able to adjust the delivery volume later, it is advisable to install a control valve on the delivery side, e.g. a ball valve, flap valve. A pressure gauge preceding the control valve as near as possible to the outlet is useful. In case of long horizontal delivery lines, a ventilation possibility should be provided. magiclab 09/12 77

78 The installation of non-return devices and shut-off elements is especially useful with long pipework. Before commissioning, containers, pipework, and connections must be thoroughly cleaned and rinsed, so that during operation no welding beads, scale or other impurities can loosen and damage the machine or other system parts. 6.5 HEATING / COOLING CONNECTIONS The basic machine as well as all other modules are additionally equipped with heating/cooling connections in the form of female threads G 1/8. One connection each is located in the inlet cover and one in the outlet chamber. They are protected with a standard closing plug, and in case of need they can be connected to suitable heating or cooling devices via hose lines using suitable screwed pipe connections. Appropriate tempering media are e.g. water, heat-transfer oil, and steam. Note following articles for assembly: If the working chamber is brought to a specified temperature, above 65 C the danger of burns exists at the non-insulated working chamber and the supply lines. In this case the hot parts must be provided with a touch guard by the user. The permissible temperature range in the double casing is 10 up to 120 C. The permissible pressure of 2 bars must not be exceeded. TECHNICAL DATA OF HOSES TO BE CONNECTED Recommended material PVDF or Teflon hose Outer diameter Ø 6mm Tolerance of outer diameter ± 0.1mm Wall thickness min. 1mm Pressure range depending on hose type, but max. 2bar Temperature range -20 C 120 C MOUNTING THE HOSE Cut hose in 90 angle and deburr. Make sure not to press the hose into oval form. Insert hose into the connection until it stops at the bolted joint. DISMOUNTING THE HOSE Press the thrust collar of the bolted joint and pull out the hose. 78 magiclab 09/12

79 6.6 STARTING THE MACHINE The magiclab is a flow machine. As a result of the high speed, a minimum liquid content of the product to be mixed is required for the function of the machine. The possible mixing ratio is strongly dependent on the product as with a too high solids content the limit of the permissible product viscosity may be reached. The machine may only run dry for a few seconds, otherwise the rotary shaft seal on the product side will be destroyed. Important Running the machine only with dry substances causes damage to the machine. Avoid supplying and processing pure dry substances. The machine is not suited for processing abrasive substances. Abrasive substances cause early wear particularly of the rotary shaft seal which may lead to undesired product leakage. When starting the machine with module UTC there is a risk of spouting medium out of the vessel. This may lead to serious effect on health or life. Switch on the drive only at the lowest speed setting. Then gradually increase the speed to the required level. Warning If the torque of the motor is high when the machine is started and the speed ratio is almost zero, the assembly of the module must be checked. Note 1. Preselect the maximum standard speed of rpm (module UTC rpm!). 2. Start the magiclab motor with Start-key on the operation panel. 3. Start feeding the liquid component. 4. Start feeding the powdery component (only with MHD and CMS module). 5. If necessary, slowly increase speed. magiclab 09/12 79

80 6.7 SWITCHING THE MACHINE OFF The machine may only run dry for a few seconds, otherwise the rotary shaft seal on the product side will be destroyed. Important The machine may only be operated for a short moment with closed valve on the discharge side. During longer operation, the frictional heat of the rotary shaft seal is no longer dissipated, which means that it heats inadmissibly and may be destroyed After having used the machine it must be cleaned. This is particularly important in case of hardening product to be mixed, as the function of the rotary shaft seal on the product side may be affected or it may be destroyed. 1. Stop feeding the powdery component (only with modules MHD and CMS). 2. Stop feeding the liquid component. 3. Stop the magiclab motor with Stop button on the operation panel. 80 magiclab 09/12

81 6.8 CALCULATION OF THE THROUGHPUT RATE The magiclab can realize a wide range of throughputs, depending on the tools. The actually possible maximum throughput and thus the calculation of the supplied product flow depends on the following factors: Viscosity of the product to be mixed Swelling properties of the product to be mixed Solids concentration of the product to be mixed Lift at the outlet Dispersing, grinding or mixing tool Grinding gap (module Colloid mill MK) Fundamentally, it applies that per unit of time only as much liquid and solids can be supplied that can be mixed and discharged by the magiclab. Moreover, it must be stated that generally the mixing result will be best if achieved close to the maximum possible throughput. In case of low throughputs, the result and a uniform liquid flow can also be improved by means of an "artificial load, e.g. a throttle at the product discharge. If no practical values are available, a test must be carried out to settle the question which product-specific maximum throughput can be realised. The standard speed of rpm must be adjusted as output speed. This applies to the basic machine as well as to all other modules. All further optimisations should be started from this speed. Fundamentally, the speed adjustment should not be higher than required by the process. An increased speed causes stronger wear particularly of the rotary shaft seal on the product side. magiclab 09/12 81

82 7. Operation 7.1 INSTALLATION The basic unit is provided with a ON/OFF switch on the controller. The controller is equipped with a ready-to-plug cable with plug. The basic unit is connected to the controller via two separate plug connections. The operation panel is connected to the basic unit and is provided with an LED for voltage indication. A graphic display allows menu navigation. Function keys: Start Stop OK Arrow upwards Arrow downwards The temperature measuring system is connected to the basic machine. 7.2 FUNCTIONS - Clear text display with language selection - Variable speed adjustment - Displays for: Nominal value of speed Actual value of speed Actual torque of motor Actual value of product temperature Actual value of remaining time in Timer mode - Timer mode - Error messages as code 82 magiclab 09/12

83 7.3 OPERATION OF THE PANEL SWITCHING ON / OFF The magiclab is switched on with the main switch on the controller. The green LED on the operation panel indicates that the machine is switched on. While the control is starting the message WAIT is displayed. As soon as the machine is ready for operation OK appears in the display. By pressing OK the module selection window appears. MODULE SELECTION Select the module with the arrow keys, to confirm your selection press OK. LANGUAGE SELECTION To select the language press the OK key in the first module selection window for 2 seconds. The language selection window appears. Select the language with the arrow keys, to confirm your selection press OK. After the language selection is completed the module selection window is displayed again. magiclab 09/12 83

84 WORKING WINDOW In the working window all relevant operating data are displayed, e.g. actual speed, nominal speed, temperature, torque and timer. The nominal speed can be set via the arrow keys, the selected value is set by pressing OK: To start the machine press the START key, to stop the machine press STOP. In the field temperature only a value is displayed when the PT100 is connected to the basic unit. The temperature of the medium is displayed. The torque display only serves for checking the motor torque. The timer shows the remaining running time. TIMER SETTING To set the timer press the OK key for 2 seconds. A window for entering the timer value appears. The timer can only be set when the machine is not started. For setting the timer press the arrow keys, the setting is realised in steps of 10 seconds. Confirm the selected timer setting with the OK key. In this window further information is displayed. Selected module Software version To return to the operating window press the OK key. After the set time the machine is stopped automatically. Use the STOP key to stop the machine before the set time. When pressing the START key again the set timer time is completed. The machine can also be started without timer setting. 84 magiclab 09/12

85 ERRORS When an error occurs a window showing a error code is displayed, which are described in chapter "Controller or motor failure: Error displayed on operating panel" see page. magiclab 09/12 85

86 8. Maintenance Danger Danger due to electrical current! Contact with electrical lines or components can have serious effects on your health or even life. Only persons with electrical/electronical training are allowed to work on the electronical components of the machine. If connected to the power supply, the system is live. Also observe the safety instructions in chapter 1 and chapter SHAFT SEAL The machine may only run dry for a short period, otherwise the rotary shaft seal on the product side will be destroyed. Important The rotary shaft seal made of a special PTFE compound can yield an excellent service life if: permissible pressure ratios prevail no abrasive product is used sufficient moistening and cooling by a continuous product flow The rotary shaft seal itself is subject to a certain degree of wear. The wear is dependent on: the pressure difference the temperature the abrasiveness of the dispersing material the speed Any damage to the seal can be detected by the following: Dispersing material escapes at the side through the two windows of the bearing lantern. Pressure drop in the product chamber with closed system. Important When changing the dispersing material, check if the material of the rotary shaft seal and the O-rings are still suitable. It may be necessary use a different material for the shaft seal. Check the state of the shaft seal before each operation. Using damaged or unsuitable shaft seals may lead to damage of the machine. 86 magiclab 09/12

87 DISASSEMBLY SEALING FLANGE AND ROTARY SHAFT SEAL The basic unit without module UTL is taken as basis for assembly (see page 28). Clean the sealing flange of all impurities. Loosen the screws (510) of the sealing flange (500). Turn the sealing flange (500) slightly, so that it can cautiously be lifted. In the process, pay attention that the centrifugal disc (406) is not lifted either, as otherwise impurities can enter into the drive. Pull the sealing flange upward off the drive shaft. Remove the circlip ring (503) with the circlip pliers. Push the rotary shaft seal (502) out of the flange with the thumbs. Check the O-ring (622) in the sealing flange for damage and exchange when necessary. Fig. Basic version without module UTL The pertaining spare parts list can be found in chapter "4.3 basic unit - module UTL". magiclab 09/12 87

88 CHECK OF THE CENTRIFUGAL DISC 406 If the bearing surface of the rotary shaft seal shows a wear pattern, the seal must be replaced as otherwise the tightness of the machine is not ensured. Important When replacing the centrifugal disc (406) attention must be paid that the O-ring (606) from the sealing set is installed. Provided that sealing materials other than FPM are used, the O-ring must be replaced as otherwise medium can penetrate into the drive and repair carried out by staff of the company IKA will then be required. DISASSEMBLY OF ROTARY SHAFT SEAL 2 Important If the rotary shaft seal is pulled off of the drive shaft, it must be ensured that no medium (particularly liquid) can enter into the subjacent bearing! Otherwise, repair carried out by staff of the company IKA will be required. Area must be cleaned before the rotary shaft seal (409) is pulled off of the distance sleeve (410), e.g. with compressed air Fig. Rotary shaft seal magiclab 09/12

89 Fig. Installation situation of lower rotary shaft seal Press rotary shaft seal (409) down so that the O-ring (613) on the lower side seals the drive. Carefully remove the escaped medium from the uncovered area, e.g. with compressed air. Remove the rotary shaft seal by pulling it upwards with the circlip pliers. CHECK OF THE SPACER RING 410 If the bearing surface of the rotary shaft seal shows a wear pattern, the seal must be replaced as otherwise the tightness of the machine is not ensured. Important When replacing the spacer ring (410) attention must be paid that the O-ring (606) from the sealing set is installed. Provided that sealing materials other than FPM are used, the O-ring must be replaced as otherwise medium can penetrate into the drive and repair carried out by staff of the company IKA will then be required. ASSEMBLY OF LOWER ROTARY SHAFT SEAL 409 When installing the rotary shaft seal pay attention to the installed O-ring (613). Important Pay attention to the correct installation position of the ring. The sealing lip must be installed so that it points towards the product side. Only this way, the sealing function of the motor can be ensured. The rotary shaft seal must not be damaged during assembly. Even smallest defects of the sealing lip result in leakage. Should, however, liquid have entered into the motor, remove the liquid, e.g. by pouring it out, and thoroughly dry the surface of the deep groove ball bearing. Afterwards, slightly grease the bearing surface with the de- magiclab 09/12 89

90 livered grease. The delivered grease should be used in any case. After a rotary shaft seal replacement with grease, it is possible that smoke is briefly developed in the area of the seal. This is burnt excess grease and has no effect on machine operation. Apply a thin layer of the delivered grease to the rotary shaft seal (409). (Make: Company Klüber, type Barrierta L55/2) Push distance sleeve (410) with O-ring (606) onto the drive shaft until it fits down on the plane surface Place mounting sleeve (7010) on the drive shaft. Fig. Mounting sleeve (item 7010) Push rotary shaft seal (409) with O-ring (613) onto the drive shaft. Remove mounting sleeve Push centrifugal disc (406) with O-ring (606) onto the drive shaft. 90 magiclab 09/12