Operating Instructions. Magnetic Drive For EasyMax

Transcription

1 Operating Instructions Magnetic Drive For EasyMax

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3 Table of Contents 1 Introduction 5 2 Safety Definition of signal warnings and symbols Product specific safety notes 6 3 Magnetic drive overview 7 4 Assembly and installation Removing motor from flange (upgrade set only) Magnetic drive assembly (upgrade set only) Setup on two piece reactor with ST Setup on single-piece reactor 10 5 Maintenance Disassembly for maintenance Cleaning Replacing the O-rings Replacing the friction bearings Using ball bearings Replacing the ball bearings Replacing the stirrer motor 14 6 Technical data 15 7 Spare parts and accessories 16 Table of Contents 3

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5 1 Introduction When an air tight reactor is required, a magnetic drive is the best possible coupling for overhead stirrers. This equipment is compatible with all EasyMax reactors. Customize your magnetic drive to fit glass or PTFE covers as well as single-piece reactors, by simply changing the stirrer shaft. Note: For more information about all the magnetic drive accessories and sets, please refer to the EasyMax product catologue. Introduction 5

6 2 Safety 2.1 Definition of signal warnings and symbols Safety notes are marked with signal words and warning symbols. These show safety issues and warnings. Ignoring the safety notes may lead to personal injury, damage to the instrument, malfunctions and false results. Signal words WARNING for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not avoided. CAUTION Attention Note for a hazardous situation with low risk, resulting in damage to the device or the property or in loss of data, or minor or medium injuries if not avoided. (no symbol) for important information about the product. (no symbol) for useful information about the product. 2.2 Product specific safety notes Your instrument represents state-of-the-art technology and complies with all recognized safety rules, however, certain hazards may arise in extraneous circumstances. If you ever have problems with your instrument, contact your authorized METTLER TOLEDO dealer or service representative Safety notes WARNING Usage Mind the following cautions while using the magnetic drive: Be careful when you mount the magnetic drive onto a glass reactor cover. You might damage the glass. When mounting the magnetic drive be sure to clamp it to the reactor properly by using appropriate clamps. WARNING Axis Be careful when laying the magnetic drive on a table: the driven shaft could be bent. Please refer to the EasyMax Operating Instructions for safety purposes. 6 Safety

7 3 Magnetic drive overview 1 EasyMax stirrer motor 2 Magnetic drive housing with outer magnet 3 Thrust disc 4 Inner magnet 5 Upper friction bearing 6 Lower friction bearing 7 Distance sleeve 8 Driven shaft 9 Magnetic drive bearing housing 10 O-rings 11 PTFE adapter ST19 - ST14 12 Stirrer shaft (Single piece reactor only) 13 Half moon blade Magnetic drive overview 7

8 4 Assembly and installation Different sets are available to fit specific reactor/cover combinations. For existing systems, an upgrade set can be offered, however some assembly is required. 4.1 Removing motor from flange (upgrade set only) Remove the upper stirrer coupling with a 2 mm allen key. Remove three crosshead screws to detach the flange. WARNING: Put the three crosshead screws away. Other screws are needed to connect the magnetic drive. If the crosshead screws are used, the connection will not be firm and the equipment may be damaged! 4.2 Magnetic drive assembly (upgrade set only) Before starting, make sure the stirrer motor and the red housing are loose from any other parts as shown in the picture. Connect the two parts using the three hexagon socket screws (with a 1.5 mm allen key). Look into the red housing from below. Turn the stirrer motor axis until the flattened part points towards the small hole on the side of the red housing. 8 Assembly and installation

9 Slip the outer magnet onto the stirrer motor axis with the grub screw pointing towards the hole on the side of the red housing. Make sure to align the flattened part on the stirrer shaft axis, the grub screw and the side hole in the red housing. Tighten the grub screw with an allen key 2.5 mm. WARNING: The outer magnet is fragile and can be damaged when exposed to mechanical stress. Connect the pressure part with four long slotted head screws M3x54. Place the thrust disc 11.5 mm in the pressure part. Disassemble in reverse order. 4.3 Setup on two piece reactor with ST14 Insert the preassembled inner magnet with output shaft and bearings into the pressure part. WARNING: Do not over tighten when connecting the adapter part to the pressure part. Tighten gently by hand to avoid damage to the threads. Connect the required stirrer shaft to the driven shaft of the magnetic coupling with a flat head screwdriver. Note: A stirrer shaft for two piece reactors can be identified by the M3 external screw thread at the bottom. Depending on the reactor size (50, 100, 400 ml), a different stirrer shaft length is available. Assembly and installation 9

10 Place the pre-assembled magnetic drive on the central ST14 port of the reactor cover. Choose an EasyMax metal stirrer blade with M3 inside screw thread and screw it to the shaft. Note: Where the stirrer shaft connects the driven shaft, the total length can be shifted by 15 mm. The stirrer shaft can be adjusted to the desired length. Note: The designated direction of propeller type stirrer blades is with the nut facing down. Now the reactor can be assembled as described in the EasyMax Operating Instructions. Disassemble in reverse order. 4.4 Setup on single-piece reactor Attach a half-moon stirrer blade to the stirrer shaft. Fasten the screw hand-tight. Note: A stirrer shaft for single piece reactors can be identified by the M3 internal screw thread located sideways at the bottom of the shaft. Depending on the reactor size (50, 100, 400 ml), a different stirrer shaft length is available. Slip the adapter ST19>ST14 over the stirrer shaft with half-moon blade. Connect the stirrer shaft to the driven shaft of the magnetic coupling with a flat head screwdriver. Push the ST19>ST14 adapter onto the ST14 with o- rings. Note: Where the stirrer shaft connects the driven shaft, the total length can be shifted by 15 mm. The stirrer shaft can be adjusted to the desired length. 10 Assembly and installation

11 Insert the assembled magnetic drive to the central ST19 port of the single-piece reactor. Disassemble in reverse order. Assembly and installation 11

12 5 Maintenance Magnetic drives are a very robust stirrer coupling solution. With proper maintenance and care, the low-wear metal parts may last for a very long time. However the air tight housing does need a minimum of maintenance for best possible performance and to avoid damage to the equipment. All parts below the pressure part can easily be cleaned by hand, in an ultrasonic bath, or in a washer. CAUTION: Bearings are wear parts and must be replaced on a regular basis. Check the bearings frequently and replace at least after 500 hours run-time. 5.1 Disassembly for maintenance 5.2 Cleaning Follow the steps in chapter Magnetic drive assembly (upgrade set only), if required in reverse order, to dismount the magnetic drive. To reach the maintainable parts, the stirrer shaft must be removed. Unscrew the adapter part from the pressure part to reach thrust disc, inner magnet, bearings and driven shaft. If necessary, use a 17 mm wrench and bench vice, to loosen the connection. If no bench vice is available, use a 37 mm wrench. For a complete disassembly of inner magnet and driven shaft, loosen the grub screws of magnet and fastening sleeve. Contaminants can be found all the way up to the thrust disc, above the inner magnet. Remove inner magnet and bearings to access all exposed areas. When cleaning the pressure part, be careful not to run water or solvent into the red housing or stirrer motor. If the pressure part requires more cleaning than wiping with a moist towel, remove it from stirrer motor and red housing. 12 Maintenance

13 For cleaning, open the stirrer; for the first time it can be quite strict, so you maybe need an open wrench key. Note: The thrust disk can fall out - put it back in the hole. WARNING: Never operate the magnetic drive without the thrust disc. Clean the friction bearings and reassamble stirrer. Note: Remove the magnet and and the spacer sleeve if necessary. 5.3 Replacing the O-rings If the O-rings are harmed, turn brittle, or fail to seal properly, they must be replaced. 5.4 Replacing the friction bearings Depending on the motor speed, temperature and duration, the friction bearings will abrase. This may result in a noisy operation and a wobbeling of the stirrer shaft. We therefore strongly recommend to check the status of the 2 friction bearings on a monthly base and replace if necessary. Maintenance 13

14 Replace the upper friction bearing with a new one. Loosen the grub screw of the driven magnet using a size 1 screwdriver and remove the magnet. WARNING: Do not lose the grub screw! Pull off the upper friction bearing and replace it. Place the driven magnet on the driven shaft so that the opening for the grub screw corresponds to the hole in the driven shaft and tighten the screw. Remove the lower friction bearing. Then slide first the bearing, then the spacer sleeve followed by the friction bearing onto the shaft. Place the spacer sleeve on the driven shaft so that the opening for the grub screw corresponds to the hole in the driven shaft. Retighten the grub screw. Place one thrust disk on the driven magnet and reinsert the driven shaft in the magnetic coupling. 5.5 Using ball bearings Ball bearings are made of stainless steel: they do not produce flakes and have a longer lifetime. When running for longer periods at high stirring speeds they may show corrosion (depending on the used reactor content). Note: Always use the ball bearing in combination with a spacer sleeve. They are available in sets of 4: - Ball bearing - Spacer sleeve 5.6 Replacing the ball bearings The ball bearings require spacer sleeves, due to their thin dimensions: Remove the driven shaft and the driven magnet. Remove the upper ball bearing. Push a spacer sleeve and a ball bearing onto the driven shaft. Place the driven magnet on the driven shaft so that the opening for the grub screw corresponds to the hole in the driven shaft. Retighten the grub screw. Remove the lower ball bearing and distance sleeve. Then slide the spacer sleeve followed by the ball bearing onto the shaft. Place the thrust disc on the driven magnet and push the driven shaft into the magnetic coupling again. 5.7 Replacing the stirrer motor If you have to replace the stirrer motor please follow the instructions in chapter Removing motor from flange (upgrade set only). 14 Maintenance

15 6 Technical data Item Description Maximum torque 20 Ncm Stirring speed range rpm Min. allowable temperature -20 C Max. allowable temperature 200 C Material Shafts, screws Alloy C-22 O-ring Kalrez 6375 Stirrer blades Alloy C-22 or PTFE Bearings PTFE, carbon Note: For additional information, please check the detailed drawing, which is shipped as hardcopy with the magnetic drive. Technical data 15

16 7 Spare parts and accessories Description Stirrer shaft 9.5 x 165 mm, Alloy C-22, for 400 ml 1-Piece reactor, incl. screws ME number Stirrer shaft 9.5 x 184 mm, Alloy C-22, for 400 ml 2-piece reactor, incl. grub screw Stirrer shaft 9.5 x 94 mm, Alloy C-22 for 50 ml 2-piece reactor, incl. grub screw Stirrer shaft 9.5 x 83 mm, Alloy C-22, for 50 ml 1-piece reactor, incl. screws Stirrer shaft 9.5 x 129 mm, Alloy C-22, for 100 ml 2-piece reactor, incl. grub screw Stirrer shaft 9.5 x 118 mm, Alloy C-22, for 100 ml 1-piece reactor, incl. screws Spare parts and accessories

17 Maintenance set EM magnetic drive (thrust disc, friction bearings, spacer sleeve) Stirrer motor EasyMax ( rpm) Outer magnet, without screw Inner magnet 20 Ncm Alloy C-22 without grub screw Grub screw M4x3, Alloy C Driven shaft 6x125 mm, Alloy C Spare parts and accessories 17

18 O-ring 23.4 x 3.53 mm Kalrez O-ring 9.25 x 1.78 mm Kalrez O-ring x 1.78 mm Kalrez Friction bearing driven for shaft PTFE/carbon (4 pcs) Thrust disk for driven shaft (2 pcs) Ball bearing for driven shaft stainless steel (4 pcs) Spare parts and accessories

19 Spacer sleeve for driven shaft, Alloy C-22 (4 pcs) Spare parts and accessories 19

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24 For more information Mettler-Toledo AG, Autochem CH-8603 Schwerzenbach, Switzerland Tel. +41 (0) Fax +41 (0) Subject to technical changes. Mettler-Toledo AG * *