IKA 06-5819, Operating Instructions Manual

Page 1: ...IKA WERKE Reg No 4343 01 IKA ULTRA TURRAX UTL 1000 10 Serial No 06 5819 OPERATING INSTRUCTIONS EN ...

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Page 3: ...epairs 9 1 4 6 Working on electrical equipment 11 1 4 7 Working on the barrier system 12 1 4 8 Observing environmental protection guidelines 13 1 5 Remaining dangers 13 2 Description 14 2 1 Construction of the ULTRA TURRAX 15 2 1 1 Sealing cartridge 15 2 1 2 Mixing tools 15 2 1 3 Drive 15 2 1 4 Frame 15 3 Specification sheet 16 3 1 Dimensions and weight 18 4 Installation 19 4 1 Securing the machin...

Page 4: ...ing tool 30 8 3 Mechanical seal cartridge 31 8 3 1 Disassembly of the mechanical seal cartridge 31 8 3 2 Assembly of the mechanical seal cartridge 31 8 4 Motor shaft 32 8 4 1 Removing the motor shaft 32 8 4 2 Assembly of the motor shaft 32 9 Ordering spare parts 33 10 Parts list ULTRA TURRAX UTL 1000 10 35 11 Seal materials and alternative 37 12 Assembly drawing 38 12 1 Detail 1 of assembly drawin...

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Page 6: ...nical documentation also corresponds to EN ISO 12100 1 2 1 3 Use as directed To prevent injury to personnel and damage to the machine the machine is only to be operated as directed The machine is designed for the production of mixtures in a fluid phase The mix tures produced are emulsions fluid fluid and suspensions fluid solid The machine is also suited for homogenization as well as for producing...

Page 7: ...e is only used for its intended purpose the machine is only operated when it is in a perfect and functional condition and the functions of the safety equipment in particular are examined regularly the necessary personal protection equipment for operating maintenance and re pair personnel is available and worn the operating instructions are always legible and available in full wherever the machine ...

Page 8: ...injury Caution This symbol indicates dangers relating to the machine material and environment in particular The most important objective of safety information is to prevent danger to persons If safety information is preceded by a warning triangle marked Danger this does not necessarily eliminate dangers for the machine material and environment If safety information is preceded by a warning triangl...

Page 9: ... are only permitted upon obtaining written authorisation from IKA Otherwise the warranty and declaration of conformity will become null and void Danger When connected to the power supply the system is live This voltage can have fatal consequences if contacted Info Subject to technical modifications ...

Page 10: ... the operator must apply protection against accidental contact with hot components Caution The machine may not run dry The mechanical seal must always be surrounded by liquid Info The machine is not suitable for adding and processing purely dry substances This can result in serious dam age to the device Info When changing the dispersion material check whether the materials of the axial face seal a...

Page 11: ...placing heavy machine components use suit able and functional load suspension devices and stop materials only Danger Prior to maintenance or repair work ensure that all parts of the machine which may need to be contacted have cooled down to ambient temperature Danger Prior to maintenance or repair work block access to the machine work area for unauthorised persons Attach in formation sign indicati...

Page 12: ...ovement of the drive shaft must be ensured by manual turning before switch ing on the drive Secure the drive against unauthorised activation Info Great care should be exercised when working on the sealing cartridge The axial face seals are made from a very brittle material and are therefore very sensitive to any kind of impact which should be avoided ...

Page 13: ... The motor voltage is indicated on the motor rating plate or in the technical data sheet Danger Repair work on the machine s electrical equipment may only be carried out by qualified electricians Check electrical equipment on a regular basis Secure loose connections Replace damaged lines cables immediately Always keep the switching cabinet closed Access is only permitted to authorised personnel wi...

Page 14: ...t regular intervals as a preven tive maintenance measure even if no damages can be detected Observe the manufacturers indications Danger Before starting the system after maintenance or repair work check that unscrewed screw connections sit secure make sure that removed reservoir covers sieves or filters have been installed again Following maintenance and repair work and prior to re commencing prod...

Page 15: ...waste water system These substances must be stored transported col lected and disposed of in suitable containers 1 5 Remaining dangers The machine was so designed that the machine itself and its accessories will not endanger personnel the product or the environment The operator s manual is so written that if all warnings and servicing requirements are observed no danger exists It can however not b...

Page 16: ...ese components are then thoroughly mixed dispersed or homogenized within in the ma chine and discharged from the machine through a discharge connection The machine does not automatically suck in the material but does have its own head with a maximum of about 20 m approx 2 bars Power is standardly furnished by a three phase motor with 3000 3600 rpm 50 60 Hz with protection class IP55 Optionally the...

Page 17: ...ividually removable and can be optimally adjusted to meet the goals of the process Their purpose is to bring the components to be mixed into contact with one another thoroughly mix them and to discharge the mixed product from the machine The machine is a single stage machine i e there is one mixing tool used rotor with one stator 3 standard tools coarse middle and fine stage which can be different...

Page 18: ...t Tri Clamp 2 Liquid outlet Tri Clamp 2 Cleaning connection Tri Clamp 1 2 Materials Product contacting parts Stainless steel 1 4404 316 L Inlet flange mixing tool Stainless steel 1 4404 316 L Lantern motor flange Al AlCuMgPb Double acting axial face seal Q1Q1VMG BQ1VMG Elastomeric working chamber FPM Three phase a c motor Operating voltage 400 690V Frequency 50 60 Hz Capacity 7 5 kW Motor speed 50...

Page 19: ...IKA WERKE 17 3 1 Locking pressure system Max Betriebsdruck 16 bar Behältervolumen 3 l Nutzinhalt 2 5 l zul Betriebstemperatur 200 C Kühlfläche 0 1 m2 Kühlschlangeninhalt 0 25 l Gewicht 7 kg ...

Page 20: ...ner volume 3 l Useful capacity 2 5 l Permissible operating temperature 200 C Cooling surface 0 1 m2 Cooling coil capacity 0 25 l Weight 7 kg 3 3 Dimensions and weight See also chapter 14 Height approx 435 mm Length approx 740 mm Width approx 400 mm Weight approx 120 kg ...

Page 21: ...ee also figure 1 Pressure gauge to display the system pressure in the barrier system Gas filling valve for pressure formation by filling with compressed air inert gas Inspection glass for the visual check of the liquid level of the barrier Drain valve to empty the reservoir Barrier filling valve to fill the reservoir without releasing the system pressure Cooling connections to cool the barrier by ...

Page 22: ...the viewing glass The quantity re quired for this level is approx 2 5 L 3 L vessel or 4 L 6 L vessel Changing of the liquid is only required if the liquid becomes contaminated After filling the circulation system and especially the sealing cartridge should be vented To do this loosen the backflow hose of the locking liquid container and wait until some liquid appears then retighten Depending on th...

Page 23: ...Depressurise the barrier system prior to maintenance and repair work Replace the hose lines at regular intervals as a preven tive maintenance measure even if no damages can be detected Observe the manufacturers indications Before starting the system after maintenance or repair work check that unscrewed screw connections sit secure make sure that removed reservoir covers sieves or filters have been...

Page 24: ...harged into any direction Danger At barrier temperatures exceeding 65 C there is a dan ger of burning at the barrier reservoir and the supply pipes In this case the hot parts must be provided with a touch guard by the user Note If water is used as a barrier it must be cooled when temperatures exceeding 85 C are reached Otherwise the seal may incur damage ...

Page 25: ...ent on a regular basis Secure loose connections Replace damaged lines cables immediately Always keep the switching cabinet closed Access is only permitted to authorised personnel with the ap propriate keys tools Never clean switching cabinets or other electrical equipment enclosures by spraying with a water pipe connection Y connection figure 2 The connections shown in the figure above are the usu...

Page 26: ...ellows expansion joint in the pipe 6 2 Short test During a short test run check again The machine has to be filled up with liquid at least water that the single acting mechanical seal is moistened and cannot run dry The direction the motor is turning according to arrow on the ventilator unit Listen for unusual mechanical noises Caution The mechanical seal may not run dry i e the machine must alway...

Page 27: ... characteristic curve and have adjustable speeds 6 3 2 Possible adjustments of the ULTRA TURRAX for a process The ULTRA TURRAX has several components which can be adjusted for a given process In addition to the individual exchangeable mixing tools can be separately removed For good predistribution it is as a principle advantageous to use a finely perforated mantle Please however note that in gener...

Page 28: ... fluid feed if needed short flushing before turning off the fluid feed 6 3 4 Adjusting the output quantity The UTL 1000 10 is designed for use with output rates of 5000 l h with standard mix ing tools The real maximum output rate and therefore the adjustment of the material flow into the machine depends upon the following factors Viscosity of the mix product Swelling behaviour of the mix product S...

Page 29: ...dispersion material The material of the slip ring As a rule it is advisable to allow the machine to run about an additional 5 minutes without the mixing product but with a flushing fluid before the machine is turned off Possible damages to the seal can be recognized by the following Leckage of liquid on the lower side of the mechanical seal at the lantern Info When changing the dispersion material...

Page 30: ...ticky and hardening materials flush immediately after finishing Depending upon the abrasiveness of the mix product the mixing tools are subject to a certain degree of wear Since the size of the shear slot especially for the disper sion level has an influence on the mixed material the tools should be checked for wear from time to time 7 3 Barrier system Daily check of the pressure gauge and the liq...

Page 31: ...e or repair work and secure with a padlock The key to this lock must be held by the person conduct ing the maintenance or repair work 8 1 Tools for assembly For assembly and disassembly it is useful to have the following tools available 1x open end or ring wrench SW10 1x open end or ring wrench SW13 1x open end or ring wrench SW17 1x open end or ring wrench SW19 1x open end or ring wrench SW22 1x ...

Page 32: ...long the shaft To protect the surface of the tools please cover sharp edges of the assembly tool 8 2 2 Assembly of the mixing tool The assembly is done in the reverse sequence of the assembly as shown in 8 2 1 To make disassembly easy coat the hubs of the tools lightly with grease During assembly insure that the O rings of each tool are placed in the groove cor rectly Info The fixing screw 730 sho...

Page 33: ...10 and pull sidewards to remove Separate the sealing cartridge 500 by pushing out of the louver 8 3 2 Assembly of the mechanical seal cartridge Assembly is done in the reverse sequence of disassembly in 8 3 1 After installing the sealing cartridge do not forget to remove the 4 safety clamps A Otherwise the shaft is blocked Info Great care should be exercised when working on the sealing cartridge T...

Page 34: ... hexagon socket head screw 421 Remove lantern 428 sidewards Loosen set screw 410 at the centrifuge disk Remove centrifuge disc 408 sidewards Loosen all hexagon socket head screws at the centrifuge disk Remove shrink disc 260 sidewards Remove driveshaft 426 sidewards 8 4 2 Assembly of the motor shaft Assembly is done in the reverse sequence of disassembly ...

Page 35: ...ollowing Enter your complete address and if different the desired delivery address Enter the part information in the table below The exact name can be found in the parts list Always give the position name and the identification number Machine type see cover Serial number see cover Contact Invoice address Pos Quant size Art no Description ...

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Page 37: ...1 U079112 Clamping set TLK 603 55x100 402 1 S104057 Circlip DIN 6885 A 6x6x18 1 4571 408 1 U077969 Schleuderscheibe centrifuge disk 410 2 T034432 Threaded pin DIN 913 M6x8 A2 420 4 S105148 Cheese head screw DIN 912 M12x25 A2 421 4 S105148 Cheese head screw DIN 912 M12x25 A2 422 2 S089234 Cover 424 8 S101612 Round screw M4x10 A2 426 1 U077974 Drive shaft BG132S 428 1 U077942 Lantern 500 1 T052558 M...

Page 38: ...e Logo UTL 1000 10 1302 2 S101531 Straight screw connection GE 12 PLR 1 4571 1308 1 U079088 Holder holder 1310 1 S101538 Locking pressure vessel AR139 1312 2 S100699 Hexagon head cap screw DIN 933 M8x20 A2 1316 2 S101727 Flachdichtung DN 8 1318 2 S101275 Tetraflex PTFE Hose DN10 NL550 CR1 2 DKL M18x1 5 90 1322 1 U079089 Adapter 1324 2 T034436 Threaded pin DIN 913 M8x10 A2 9980 1 U080323 Motor asse...

Page 39: ... The standard material com bination used is stationary seal face material rotating seal face material O rings springs housing parts Q1 silicon car bide Q1 silicon car bide V16 FPM M Hastelloy C 4 G CrNiMo steel 1 4571 alternative B carbon graphite approved for foodstuffs E EPDM or K perfluoro caoutchouc ...

Page 40: ...IKA WERKE 38 12 Assembly drawing ...

Page 41: ...IKA WERKE 39 12 1Detail 1 of assembly drawing ...

Page 42: ...IKA WERKE 40 12 2Detail 2 of assembly drawing only with option base frame ...

Page 43: ...IKA WERKE 41 13 Dimension sheet ...

Page 44: ...hrink disc tightened unevenly Tighten all screws acc to documentation Device badly aligned Realign device Axial face seal Replace axial face seal Static O ring seal between the housing parts leaks Place O rings carefully into the groove and re place them if damaged Flanged connections leak if available Retighten the connection replace defective seals Outlet valve closed while ma chine is running D...

Page 45: ...up Remove deposits in the machine and or pipework trapped air in the mixing chamber or suction pipe par ticularly in case of horizontal suction pipe Vent device and or suc tion pipe Wrong direction of rotation Change 2 phases of the current supply too low speed Increase the speed wear of the interior parts Replace worn parts unsufficient torque at the shrink disc Tighten all screws acc to document...

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Page 47: ...ted by the EC directives In case of a modification of the machine which is not co ordinated with us this decla ration will no longer be valid Designation of the machine ULTRA TURRAX Machine type UTL 1000 10 Serial no 06 5819 Year of construction 2007 Relevant EC directives 98 37 EC Appendix II A Directive relating to machinery Applied harmonised standards EN ISO 12100 1 Safety of machinery EN ISO ...

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