u078310 - cole-parmer · thread. even minor, invisible damage can lead to imbalance and even affect...

U078310

Reg. Nr. 4343-01

IKA® magicLAB®

OPERATING MANUAL EN

mag icLAB® 09 /12 2


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 - 79219 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 re-quirements 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: 2006/42/CE (machinery directive) 2006/95/CE (Low voltage directive) Applied harmonised standards: EN ISO 12100-1 (Safety of machinery) EN ISO 12100-2 (Safety of machinery) EN ISO 13857(Safety of machinery) EN 349 (Safety of machinery) EN 60204 (Safety of machinery) EN 61326 (Electrical equipment for measurement, control and laboratory use) EN 61010 (Safety requirements of laboratory devices) EN 61010 does not apply for the Controller U079209 Date: 01.01.2010

Manufacturer’s signature: Peter Wanninger Information on the undersigned: Managing Director Authorised person for documentation: Karen Klem


OPERATING MANUAL EN 1. For your safety..............................................................................................................................7

1.1 General dangers ...................................................................................................................7 1.2 Intended use..........................................................................................................................7 1.3 Safety precautions................................................................................................................8 1.4 General safety instructions...............................................................................................10 1.5 Basic safety precautions during normal operation.......................................................11 1.6 Basic safety instructions during service and maintenance .........................................14 1.7 Work on the electrical equipment....................................................................................15 1.8 Observe the environmental protection regulations.......................................................15 1.9 Other dangers ....................................................................................................................16

2. Specifications.............................................................................................................................17 2.1 Electrical data.....................................................................................................................19

3. Unpacking ..................................................................................................................................20 4. Description – Basic unit and modules ...................................................................................21

4.1 Modular design...................................................................................................................22 4.2 Assembly information........................................................................................................23 4.3 Basic unit – Module UTL ..................................................................................................26 4.4 Module DISPAX REACTOR® DR ...................................................................................32 4.5 Module colloid mill MK ......................................................................................................37 4.6 Module MHD.......................................................................................................................45 4.7 Module CMS.......................................................................................................................52 4.8 Module UTC .......................................................................................................................61

5. Brief test .....................................................................................................................................69 6. Working with the machine .......................................................................................................70

6.1 Information on working with product...............................................................................72 6.2 Operation using flow-through processes .......................................................................73 6.3 Accessories for circulation processes – MicroPlant.....................................................74 6.4 Connector design – Connection of the customer .........................................................77 6.5 Heating / Cooling connections.........................................................................................78 6.6 Starting the machine .........................................................................................................79 6.7 Switching the machine off ................................................................................................80 6.8 Calculation of the throughput rate...................................................................................81

7. Operation....................................................................................................................................82 7.1 Installation...........................................................................................................................82 7.2 Functions.............................................................................................................................82 7.3 Operation of the panel ......................................................................................................83

8. Maintenance ..............................................................................................................................86 8.1 Shaft seal ............................................................................................................................86 8.2 Changing O-rings...............................................................................................................92 8.3 Generators..........................................................................................................................93 8.4 Dispersion Tools UTC NK for module UTC..................................................................93 8.5 Bearing................................................................................................................................93 8.6 Drive shaft...........................................................................................................................93 8.7 Electrical equipment..........................................................................................................93

9. Cleaning .....................................................................................................................................95 9.1 Basic machine....................................................................................................................95 9.2 Controller housing .............................................................................................................95 9.3 Dispersion tools and product contacting parts..............................................................95

10. Troubleshooting.....................................................................................................................96


10.1 Failure of magicLAB® controller...............................................................................99 11. Dimension sheets................................................................................................................104

11.1 MODULE UTL...........................................................................................................104 11.2 MODULE DR.............................................................................................................105 11.3 MODULE MK ............................................................................................................106 11.4 MODULE MHD .........................................................................................................107 11.5 MODULE CMS .........................................................................................................108 11.6 MODULE UTC..........................................................................................................109 11.7 Micro Plant.................................................................................................................110

12. Scale Up ...............................................................................................................................111 13. IKA .........................................................................................................................................112


1. For your safety 1.1 GENERAL DANGERS Observe all pertinent safety instructions and directives, as well as work safety and accident-prevention 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 ob-serve 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 (gase-ous/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 ho-mogenising 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 ma-chines 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 over-heating, a minimum distance of 10 cm should be kept between the intake and exhaust air grids of the magicLAB® controller and other objects.


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 inter-vals,

• required personal protective equipment for operating, maintenance, and repair person-nel 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 author-ised personnel,

• this personnel, at regular intervals, shall receive instruction regarding all questions con-cerning work safety and environmental protection and that they are familiar with the op-erating 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 re-sidual 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

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.

Warning

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.


Caution

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.

Hot surface

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.

Important

Under this symbol important information is given for appropri-ate use of the machine. Nonobservance of these instructions can lead to disturbance of the machine or the surroundings.

Note

Under this symbol information for use are given. This information will help you to make optimum use of all func-tions of your machine.


1.4 GENERAL SAFETY INSTRUCTIONS

Danger

Observe all pertinent safety instructions and directives, as well as work safety and accident-prevention regulations for labora-tory use.

Danger

Modifications of the system and parts of it are only allowed with written approval of IKA®. Otherwise the warranty and the decla-ration of conformity will become void!

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.

Danger

Starting the machine without any module and connecting de-vices 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 com-pletely.

Note

Subject to technical modifications.


1.5 BASIC SAFETY PRECAUTIONS DURING NORMAL OPERATION

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!

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 instruc-tions!

Danger

The magicLAB® may not be used to process inflammable or ex-plosive 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 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.

Danger

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!)

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 inad-vertent starting!


Hot surface

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

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.

Important

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

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.

Important

The machine with module MK may only be switched on after ra-dial gap adjustment. Otherwise there is a risk of damaging the machine.

Important

Running the machine only with dry substances causes damage to the machine. Avoid supplying and processing pure dry sub-stances.

5

Important

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 ma-terials. In case of doubt, please contact your supplier or the IKA®-Werke directly.


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.

Important

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.

Important

Wear personal protective equipment in accordance with the hazard category of the medium to be processed.


1.6 BASIC SAFETY INSTRUCTIONS DURING SERVICE AND MAINTENANCE

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 con-tinue be life for some time after the mains plug is pulled. Con-tact to these live components has serious effects on health and life.

Danger

The machine may only be maintained by qualified and author-ised persons observing the safety instructions and who are fa-miliar with the operating instructions (also of the subassem-blies) and who are able to follow these instructions!

Danger

Before carrying out any maintenance or repair work block the access to the work area of the machine to unauthorised per-sons! Attach or erect a warn sign that draws the attention to the maintenance or repair work!

Hot surface

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!

Caution

Ensure proper disposal of environmentally hazardous lubricat-ing, cooling or cleaning agents!


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 ma-

chine is switched off! • Always keep the control cabinet closed! Access only for au-

thor-ised persons with key/tool! • Never clean control cabinets and other housings of the elec-

trical 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!


1.9 OTHER DANGERS The machine has been designed in such a way that neither the machine itself nor its acces-sories may present any danger to persons, products or the environment. The operating in-structions 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 pre-vention of accidents and the employer's liability insurance associations.


2. Specifications OPERATION AS BASIC UNTI WITH MODULE UTL Nominal rotor speed 16000 rpm Rotor speed range 3000 – 26000 rpm Nominal torque 0.28 Nm (for a short interval max. 0.32 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 16000 rpm Rotor speed range 3000 – 26000rpm 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 25400 rpm Rotor speed range 3000 – 26000 rpm OPERATION AS MK Nominal rotor speed 16000 rpm Rotor speed 3000-26000 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 16000 rpm Rotor speed 3000-20000 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 11000 rpm Rotor speed 3000-16000 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 10000-24000 rpm Dimensions (W x L x H) 170 mm x 270 mm x 420 mm


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 -500 mbar Double chamber: Max. permissible temperature double chamber continuous operation 80 °C 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 10-35 °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 6 kg Weight controller 4.5 kg Weight complete system in transport case 20 kg Dimensions controller (W x L x H) 250 mm x 160 mm x 300 mm Dimensions transport case (W x L x H) 290 mm x 410 mm x 440 mm MAX. THROUGHPUT These values are measured at a nominal rotor speed of 16000 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 approx. 80 l / h Module MK approx. 200 l / h Module MHD, total throughput approx. 60 l / h Module CMS approx. 1000 l / h RECOMMENDED VOLUMETRIC RANGE UTC Module UTC with UTC-NK-18G 0.01 – 0.5 l Module UTC with UTC-NK-25G 0.05 – 2.5 l Module UTC with UTC-NK-25F 0.05 – 2 l MATERIAL Product contacting parts stainless steel / 1.4404+1.4571 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 / 1.4301


2.1 ELECTRICAL DATA Nominal voltage 220 - 240 V / PE Frequency 50 – 60 Hz Power output 900 W Motor speed 3000 – 26000 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 220-240 V / PE Max. supply voltage fluctuation ± 5% of mains voltage Mains frequency 50 – 60 Hz Fuse protection (to be provided by customer) 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 50178 can no longer be ob-served. 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. 2000 m TEMPERATURE MEASUREMENT Measurement range temperature 0-180 °C Accuracy temperature measurement ± 1 °C TIMER-FUNCTION Time range 0 – 99 min Time steps 10 s


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 dam-age. It is important that any damage is detected as soon as the items are unpacked. A re-cord 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.

Fig.: Delivery range magicLAB® with transport box, controller and operating unit

Basic unit with module UTL

Operating unit

Controller Transport box


4. Description – Basic unit and modules

The basic unit of the magicLAB® is a single-stage, high-quality and multipurpose disper-sion machine for continuous dispersion of liquids. The basic version can assembled with different dispersion modules. The drive unit is a high-speed 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.

Operating panel

Basic unit

Module UTL


4.1 MODULAR DESIGN The magicLAB® has a modular design. In its basic version, the magicLAB® will be deliv-ered ready for connection.

Fig. Module UTL 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.

Inlet Outlet

Generator 4M

Double casing in- and outlet


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 T056917 Tool bag 20 1 T057205 Pliers S1 30 1 U081238 Open end wrench OW 8/10 40 1 U081239 Open end wrench OW 11/13 50 1 U081240 Open end wrench OW 6 60 1 U081241 Open end wrench OW 18 70 1 U081242 Hexagon wrench OW 80 1 U082319 Hexagon wrench OW 3 90 1 U081715 Lubricating grease

20

30

40

50

80

70

60


SAFETY NOTES

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.

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 inad-vertent starting!

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 mounted. If necessary tighten the screws.

Caution

During the assembly of the modules there is a danger of cutting on the sharp edged tools. Wear protective gloves.

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 dur-

ing 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 fit-ting parts together.

• Tighten the screws of the sidewise clamps at 5.9 Nm fastening

torque.


Note

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 UH1 64-62 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.


4.3 BASIC UNIT – MODULE UTL

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 be-tween 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 re-spective 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.

Operating panel

Basic unit

Module UTL generator 4M

Intake

Outlet

Double chamber inlet

Double chamber outlet

Clamp


A DC-brushless motor is used as the drive with a speed range of 3000 – 26000 rpm. The drive shaft is the rotor shaft for the dispersion tools. The circumferential speed at the pe-riphery of the rotor is 23 m/s on 16000 rpm and 40m/s on 25400 rpm. As the circumferential speed of the rotor has a decisive influence on the dispersion result, the magicLAB® con-troller 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® oper-ating panel. In case of an overload the motor is switched off by means of a thermal motor protection machine. GENERATORS

2G 4M

6F 2P


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”.


DRAWING

Fig. Exploded view basic unit with module UTL


SPARE PART LIST OF BASIC UNIT WITH MODULE UTL Spare part list number U078310 Pos Items Ident no. Designation 100 1 U082838 Drive 200 1 U077215 Housing complete 406 1 U084091 Sling disc 409 1 U085141 Axial face seal cartridge cpl. 410 1 U085317 Distance sleeve for rotary shaft seal 500 1 U076606 Sealing flange complete 501 1 U076580 Sealing flange 502 1 U078183 Rotary shaft seal 503 1 T057196 Circlip 510 2 S103789 Screw DIN 6912 M4x10-A4 600 1 U081594 Sealing set basic unit with module UTL 710 1 U074985 Pumping chamber 711 1 U076117 Clamping flange 712 1 U074989 Sealing disk 715 2 U075095 Connection for hose 720 2 U078168 Clamp, complete 730 1 U074980 Pressure nut 731 1 U074982 Distance sleeve 732 2 U075557 Rotor 0 900 1 U075042 Generator pack 4M 904 1 U074965 Rotor 4M * 906 1 U076012 Stator 4M * 1500 1 U078108 Temperature sensor 1501 1 S108403 Clampspannring DN ½"-3/4" 1502 1 S108402 Clamp sealing DN ½" 3000 1 U079206 Controller magicLAB® 3020 1 U078261 Operating panel 7000 1 U077001 Case until Controller serial no. 02.100105 7000 1 U082678 Case as of Controller serial no. 02.100105 7001 1 U081013 Case inlay 1 7002 1 U081014 Case inlay 2 7010 1 U076585 Assembling sleeve

* Only available as generator pack!


STANDARD PARE PART LIST SEALING SET FPM BASIC UNIT WITH MODULE UTL Spare part list number U081594 Pos Items Ident no. Designation 606 2 S104992 O-ring FPM 8x1,5 608 4 U076171 O-ring FPM 56.87x1.78 610 2 U076170 O-ring FPM 37.82x1.78 612 2 U077597 O-ring FPM 31.47x1.78 613 1 T033330 O-Ring FPM 20,35x1,78 622 1 S109087 O-ring FPM 28.3x1.78 1502 1 S108402 Clamp sealing FPM DN ½"

SPARE PARTS LIST FOR OPTIONAL SEALING SET EPDM(FDA) BASIC UNIT WITH MODULE UTL Stücklistennummer U083618 Pos Items Ident no. Designation 606 2 S109311 O-ring EPDM(FDA) 8x1.5 608 4 U082303 O-ring EPDM(FDA) 56.87x1.78 610 2 U082304 O-ring EPDM(FDA) 37.82x1.78 612 2 U082305 O-ring EPDM(FDA) 31.47x1.78 613 1 T060341 O-Ring EPDM(FDA) 20,35x1,78 622 1 T049006 O-ring EPDM(FDA) 28.3x1.78 1502 1 T049012 Clamp sealing EPDM(FDA) DN ½“

SPARE PARTS LIST FOR OPTIONAL SEALING SET FFPM BASIC UNIT WITH MODULE UTL Spare part list number U084051 Pos Items Ident no. Designation 606 2 U084037 O-ring FFPM 8x1.5 608 4 U084038 O-ring FFPM 56.87x1.78 610 2 U084042 O-ring FFPM 37.82x1.78 612 2 U084016 O-ring FFPM 31.47x1.78 613 1 T061182 O-Ring FFPM 20,35x,78 622 1 T057692 O-ring FFPM 28.3x1.78 1502 1 U081162 Clamp sealing Gylon blue DN ½“


4.4 MODULE DISPAX REACTOR® DR

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 sus-pensions. With 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 16000 rpm and 25400 rpm in case of the module DRS. This cor-responds 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.

Outlet

Inlet

2 additional generators


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 ma-chine. 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 f lange

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 clock-

wise. The distance bush has got spanner flats for counter. - Attach the stator (806) with O-rings (608, 610) on the other stator. - Attach the inle t 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”.


DRAWING

Fig. Exploded view basic unit with module DR


SPARE PART LIST MODULE DR Spare part list number U078352 Pos Items Ident no. Designation 600 1 U079668 Sealing set module DR 800 1 U075041 Generator pack 2G 804 1 U074959 Rotor 2G * 806 1 U076011 Stator 2G * 1000 1 U075043 Generator pack 6F 1004 1 U074966 Rotor 6F * 1006 1 U076009 Stator 6F *

* Only available as generator pack! SPARE PART LIST STANDARD SEALING SET FPM MODULE DR Spare part list number U079668 Pos Items Ident no. Designation 606 2 S104992 O-ring FPM 8x1.5 608 6 U076171 O-ring FPM 56.87x1.78 610 4 U076170 O-ring FPM 37.82x1.78 612 2 U077597 O-ring FPM 31.47x1.78 613 1 T033330 O-Ring FPM 20,35x1,78 622 1 S109087 O-ring FPM 28.3x1.78 1502 1 S108402 Clamp sealing FPM DN ½"

SPARE PARTS LIST FOR OPTIONAL SEALING SET EPDM(FDA) MODULE DR Spare part list number U082306 Pos Items Ident no. Designation 606 1 S109311 O-ring EPDM(FDA) 8x1.5 608 6 U082303 O-ring EPDM(FDA) 56.87x1.78 610 4 U082304 O-ring EPDM(FDA) 37.82x1.78 612 2 U082305 O-ring EPDM(FDA) 31.47x1.78 613 1 T060341 O-Ring EPDM(FDA) 20,35x1,78 622 1 T049006 O-ring EPDM(FDA) 28.3x1.78 1502 1 T049012 Clamp sealing EPDM(FDA) DN ½“


SPARE PARTS LIST FOR OPTIONAL SEALING SET FFPM MODULE DR Spare part list number U084050 Pos Items Ident no. Designation 606 2 U084037 O-ring FFPM 8x1.5 608 6 U084038 O-ring FFPM 56.87x1.78 610 4 U084042 O-ring FFPM 37.82x1.78 612 2 U084016 O-ring FFPM 31.47x1.78 613 1 T061182 O-Ring FFPM 20,35x,78 622 1 T057692 O-ring FFPM 28.3x1.78 1502 1 U081162 Clamp sealing Gylon blue DN ½“


4.5 MODULE COLLOID MILL MK

FUNCTIONAL PRINCIPLE OF THE COLLOID MILL MK The magicLAB® with the module colloid mill MK is a high-performance colloid mill includ-ing a grinding gear, which, like the basic machine, is designed according to the rotor-stator-principle. However, the grinding gear design differs considerably from that of the basic ma-chine. The grinding gap between rotor and stator has a conical design and a llows a con-tinuous 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.

Adjusting ring

Locking screw

Outlet

Inlet


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 26000 rpm. Operation with the module colloid mill MK should first be started at the standard speed of 16000 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® oper-ating 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] 0 0 0

180 1/2 0.159 270 3/4 0.239 360 1 0.318 450 1 1/4 0.398 540 1 1/2 0.477 630 1 3/4 0.557 720 2 0.636

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)


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 an-ticlockwise 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 clock-

wise. 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”.


DRAWING

Fig. Exploded view basic unit with module MK


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 pump-

ing chamber (710). The inlet flange (704) is lifted up, too. - Remove the Inlet f lange (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 re-

spective bore and the inlet socket is fixed in the slot. The stator unit (900) is delivered completely mounted. DRAWING

Fig. Drawing generator unit


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


SPARE PART LIST MODULE MK Spare part list number U076662 Pos Items Ident no. Designation 600 1 U079669 Sealing set MODULE MK 704 1 U075732 Inlet flange DN ¾" MK 710 1 U075761 Pumping chamber MK 716 1 U075744 Adjusting ring 722 1 U075813 Bolt 731 1 U075728 Sleeve MK 735 1 U077205 Knurled nut 736 1 U081630 Threaded pin 900 1 U083553 Stator unit* 904 1 U075888 Rotor MK

* Only available as stator unit SPARE PARTS LIST STATOR UNIT SPARE PART LIST NUMBER U083553 Pos Items Ident no. Designation 611 1 U075745 O-ring FPM(FDA) 31x1.5 716 1 U075744 Adjusting ring 722 1 U075813 Bolt 902 1 U075887 Stator MK

SPARE PART LIST MODULE MKO SPARE PART LIST NUMBER U079664 Pos Items Ident no. Designation 610 1 U075749 O-ring FPM(FDA) 23,52x1,78 611 1 U075745 O-ring FPM(FDA) 31x1.5 612 1 U066526 O-ring FPM (FDA) 36.17x2,62 704 1 U075732 Inlet flange DN 3/4" MAGICLAB 710 1 U075761 Pumping chamber MK clamp 1/2" 716 1 U075744 Adjusting ring Rg7 722 1 U075813 Bolt DIN 7 4m6x14-A2 731 1 U075728 Sleeve MK 735 1 U077205 Knurled nut DIN467-M4-NI 736 1 U081630 Threaded pin GN913.5-M4-12-KU 900 1 U083555 Stator unit MKO* 904 1 U080674 Rotor MKO

* Only available as stator unit SPARE PARTS LIST STATOR UNIT SPARE PART LIST NUMBER U083555 Pos Items Ident no. Designation 611 1 U075745 O-ring FPM(FDA) 31x1.5 716 1 U075744 Adjusting ring 722 1 U075813 Bolt 902 1 U080685 Stator MKO


SPARE PART LIST STANDARD SEALING SET FPM MODULE MK/MKO Spare part list number U079669 Pos Items Ident no. Designation 606 2 S104992 O-ring FPM 8x1.5 608 2 U076171 O-ring FPM 56.87x1.78 610 1 U075749 O-ring FPM 23.52x1.78 611 1 U075745 O-ring FPM 31x1.5 612 2 U077597 O-ring FPM 31.47x1.78 613 1 T033330 O-Ring FPM 20,35x1,78 615 1 U066526 O-ring FPM 36.17x2.62 622 1 S109087 O-ring FPM 28.3x1.78 1502 1 S108402 Clamp sealing FPM DN ½"

SPARE PARTS LIST FOR OPTIONAL SEALING SET EPDM(FDA) MODULE MK/MKO Spare part list number U083619 Pos Items Ident no. Designation 606 2 S109311 O-ring EPDM(FDA) 8x1.5 608 2 U082303 O-ring EPDM(FDA) 56.87x1.78 610 1 U083620 O-ring EPDM(FDA) 23.52x1.78 611 1 U083621 O-ring EPDM(FDA) 31x1.5 612 2 U082305 O-ring EPDM(FDA) 31.47x1.78 613 1 T060341 O-Ring EPDM(FDA) 20,35x1,78 615 1 U083159 O-ring EPDM(FDA) 36.17x2.62 622 1 T049006 O-ring EPDM(FDA) 28.3x1.78 1502 1 T049012 Clamp sealing EPDM(FDA) DN ½“

SPARE PARTS LIST FOR OPTIONAL SEALING SET FFPM MODULE MK/MKO Spare part list number U084054 Pos Items Ident no. Designation 606 2 U084037 O-ring FFPM 8x1.5 608 2 U084038 O-ring FFPM 56.87x1.78 610 1 U084041 O-ring FFPM 23.52x1.78 611 1 U084040 O-ring FFPM 31x1.5 612 2 U084016 O-ring FFPM 31.47x1.78 613 1 T061182 O-Ring FFPM 20,35x1,78 615 1 U084042 O-ring FFPM 36.17x2.62 622 1 T057692 O-ring FFPM 28.3x1.78 1502 1 U081162 Clamp sealing Gylon blue DN ½“


4.6 MODULE MHD

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: Dosing device Remark Proportioning of the solid component

Volumetric proportioning screw

Reduced expenditure, vary-ing proportioning accuracy

Gravimetric ratio weigher High expenditure, high pro-portioning accuracy

Proportioning of the liquid component

Hose pump Simple, not suitable for all products

Gear pump High expenditure, suitable for most products

Outlet

Powder inlet

Liquids inlet

Double chamber inllet



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.

Fig. Module MHD The speed of the magicLAB® with the module MHD can be adjusted from 3000 rpm to 20000 rpm. Operation with the module MHD should first be started at the standard speed of 16000 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® oper-ating 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 de-signed 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.


Liquids inlet

Double chamber inlet

Powder inlet

Outlet


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 con-sists 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 un-der 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 dis-charged 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 real-ised. 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. When 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".


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 f lange

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 inle t 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”.


DRAWING

Fig. Exploded view basic unit with module MHD


SPARE PART LIST MODULE MHD Spare part list number U075262 Pos Items Ident no. Designation 600 1 U079670 Sealing set MODULE MHD 704 1 U075268 Inlet flange DN 25 705 1 U075269 PTFE-insert 708 1 U075271 Double chamber housing 715 2 U075095 Connection for hose 802 1 U075278 Feeding worm 804 3 U075272 Mixing tool 902 1 U075273 Injector chamber 1000 1 U075039 Generator pack 2P 1004 1 U074953 Pumping wheel P* 1006 1 U076011 Stator 2G*

* Only available as generator pack! SPARE PART LIST STANDARD SEALING SET FPM MODULE MHD Spare part list number U079670 Pos Items Ident no. Designation 606 2 S104992 O-ring FPM 8x1.5 608 5 U076171 O-ring FPM 56.87x1.78 610 3 U076170 O-ring FPM 37.82x1.78 612 2 U077597 O-ring FPM 31.47x1.78 613 1 T033330 O-Ring FPM 20,35x1,78 615 1 U075745 O-ring FPM(FDA) 31x1.5 622 1 S109087 O-ring FPM 28.3x1.78 1502 1 S108402 Clamp sealing FPM DN ½"

SPARE PARTS LIST FOR OPTIONAL SEALING SET EPDM(FDA) MODULE MHD Spare part list number U083623 Pos Items Ident no. Designation 606 1 S109311 O-ring EPDM(FDA) 8x1.5 608 5 U082303 O-ring EPDM(FDA) 56.87x1.78 610 3 U082304 O-ring EPDM(FDA) 37.82x1.78 612 2 U082305 O-ring EPDM(FDA) 31.47x1.78 613 1 T060341 O-Ring EPDM(FDA) 20,35x1,78 615 1 U083621 O-ring EPDM(FDA) 31x1.5 622 1 T049006 O-ring EPDM(FDA) 28.3x1.78 1502 1 T049012 Clamp sealing EPDM(FDA) DN ½“


SPARE PARTS LIST FOR OPTIONAL SEALING SET FFPM MODULE MHD Spare part list number U084052 Pos Items Ident no. Designation 606 2 U084037 O-ring FFPM 8x1.5 608 5 U084038 O-ring FFPM 56.87x1.78 610 3 U083974 O-ring FFPM 37.82x1.78 612 2 U084016 O-ring FFPM 31.47x1.78 613 1 T061182 O-Ring FFPM 20,35x1,78 615 1 U084040 O-ring FFPM 31x1.5 622 1 T057692 O-ring FFPM 28.3x1.78 1502 1 U081162 Clamp sealing Gylon blue DN ½“


4.7 MODULE CMS

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. 0.1-0.5 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 16000 rpm, however, the machine should be run at the standard speed of 12000 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.

Liquids inlet

Outlet

Powder inlet


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 sec-tion 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) with-out 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. Disas-

sembly 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 seal-ing is not damaged.

- Attach the pumping chamber CMS (710) carefully on the machine with the outlet to the front side.

- Attach the inle t 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).


- Put the both sidewise clamps (720) on the machine and tighten the screws with the re-quired 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.

Note

When using accessories for operation using circulation proc-esses, with vacuum and pressure, or using other components, please observe the special operating instructions "magicLAB Plant Accessories".


DRAWING


Fig. Exploded view basic unit with module CMS


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 dis-

assembly 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.

1. 2.

3.


DRAWING

Fig. Generator CMS


SPARE PART LIST MODULE CMS Spare part list number U075333 Pos Items Ident no. Designation 415 1 U075338 Distance sleeve 500 1 U076699 Sealing flange cpl. CMS 501 1 U075339 Sealing flange CMS 502 1 U075016 Rotary shaft seal 503 1 T057196 Circlip 600 1 U079671 Sealing set MODULE CMS 704 1 U076082 Inlet flange Clamp ¾" 708 1 U075344 Inlet housing Clamp ¾" 710 1 U075340 Pumping chamber CMS 711 1 U080101 Clamping flange 712 1 U075388 Sealing disk 713 2 U075095 Connection for hose 730 1 U075341 Pressure nut 800 1 U075334 Generator pack CMS 804 1 U075335 Rotor solid/liquid * 806 4 U080118 Screw DIN 84-M2.5x25 * 808 1 U075336 Rotor, outlet * 810 1 U075373 Rotary shaft seal 1000 1 U078378 Bottom part clamp CMS 7050 1 U091468 Disassembly tool WeDi CMS

* Only available as generator pack! SPARE PART LIST STANDARD SEALING SET FPM MODULE CMS Spare part list number U079671 Pos Items Ident no. Designation 606 4 S104992 O-ring FPM 8x1.5 608 3 U076171 O-ring FPM 56.87x1.78 610 2 U076170 O-ring FPM 37.82x1.78 612 1 S102246 O-ring FPM 32x2 613 1 T033330 O-Ring FPM 20,35x1,78 622 1 S109087 O-ring FPM 28.3x1.78 630 1 T052151 O-ring FPM 10x1 636 1 S100336 O-ring FPM 18x1.5


SPARE PARTS LIST FOR OPTIONAL SEALING SET EPDM(FDA) MODULE CMS Spare part list number U083622 Pos Items Ident no. Designation 606 4 S109311 O-ring EPDM(FDA) 8x1.5 608 3 U082303 O-ring EPDM(FDA) 56.87x1.78 610 2 U082304 O-ring EPDM(FDA) 37.82x1.78 612 1 S107681 O-ring EPDM(FDA) 32x2 613 1 T060341 O-Ring EPDM(FDA) 20,35x1,78 622 1 T049006 O-ring EPDM(FDA) 28.3x1.78 630 1 T052549 O-ring EPDM(FDA) 10x1 636 1 T045161 O-ring EPDM(FDA) 18x1.5

SPARE PARTS LIST FOR OPTIONAL SEALING SET FFPM MODULE CMS Spare part list number U084053 Pos Items Ident no. Designation 606 4 U084037 O-ring FFPM 8x1.5 608 3 U084038 O-ring FFPM 56.87x1.78 610 2 U083974 O-ring FFPM 37.82x1.78 612 1 U084039 O-ring FFPM 32x2 613 1 U084016 O-ring FFPM 31.47x1.78 622 1 T057692 O-ring FFPM 28.3x1.78 630 1 T057719 O-ring FFPM 10x1 636 1 S108081 O-ring FFPM 18x1.5


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 ro-tor/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 26000 rpm. Operation with the module UTC should first be started at the standard speed of 10000 rpm, and all further optimisations should be realised on the basis of this speed. The optimum speed is 24000 rpm. This corresponds to a circumferential speed of 12-16 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.


CONNECTIONS The magicLAB® with module UTC can be combined with IKA®-dispersing tools of the se-ries UTC-NK. ADDITIONAL SAFETY INSTRUCTIONS MODULE UTC

Danger

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.

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.

Warning

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 gradu-ally increase the speed to the desired level.

Important

Make sure that no liquid enters into the drive unit, otherwise there is a risk of damage to the machine.

Important

During operation it is possible that the processed medium abrais impurified by abrsives of the machine or of the rotating acces-sory parts.

Important

The dispersion tool is not suited for continous operation.


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 al-kali 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)

Note

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.


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”.


DRAWING

Fig. Basic unit with module UTC

Fig. 3D-view of basic unit with moduleA UTC


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 ar-

rested 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 rotor- stator 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).


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


SPARE PART LIST DISPERSING TOOL S 25 N Parts list number U078657 Pos items Ident number Designation 730 1 U080178 intermediate flange 731 1 U078104 ball bearing 732 1 T057196 circuit clip 733 1 U080553 spring wave 734 1 S100345 O-Ring FPM 28x2 735 1 U078601 distance sleeve 901 1 U080950 flange for dispersion tool 902 1 U078599 spring catch 903 1 U078600 hand screw 905 1 U079845 coupling 906 1 U084211 pin 1102 1 U077610 Stand shaft 1104 1 S102327 Counter nut DIN 934 M12-A4 7001 1 U079758 Flat key 7002 1 U079759 Shaft key 7003 1 U079760 Generator key SPARE PARTS LIST DISPERSION TOOL UTC-NK Parts list number U084199 Pos items Ident number Designation 10 1 U082953 Shaft tube 20 1 U084228 Rotor shaft 30 1 U084225 Friction ring 40 1 U084224 Sleeve 50 1 U084219 Slotted ring bearing 60 1 U080394 Rotor 18G 70 1 U080393 Stator 18G

SPARE PARTS LIST OPTION ROTOR / STATOR Identnummer Bezeichnung U080396 Rotor 25G U080395 Stator 25G U080398 Rotor 25F U080397 Stator 25F


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 con-

nected. 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.


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

Caution

Never reach into the mixing chamber. There is a risk of injury due to rotating mixing tools.

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 dur-

ing 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 ma-

chine. • During assembly pay attention that the O-rings between the in-

dividual parts are inserted correctly in the groove when fitting parts together.

• Tighten the screws of the sidewise clamps at 5.9 Nm fastening

torque.

Important

The machine may only run dry for a short period, otherwise the rotary shaft seal on the product side will be destroyed. The machine with module MK may only be switched on after radial gap adjustment. Otherwise there is a risk of damaging the ma-chine.


Note

With certain products or product characteristics, e.g. high viscos-ity or a combinations of fine generators, and at very high rota-tional 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.


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 ex-changeable 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 com-ponent or to circulate the product to be mixed, pumps working according to the displace-ment 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.


6.2 OPERATION USING FLOW-THROUGH PROCESSES

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 ma-terial which is compatible with the product and show a sufficient pressure, temperature and media resistance.

Inlet

Outlet


6.3 ACCESS

u078310 - cole-parmer · thread. even minor, invisible damage can lead to imbalance and even affect...

Documents