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Summary of Contents for IKA ULTRA-TURRAZ UTL 1000/10
- Page 1 ® WERKE ® ® ® ® ® U L T R A - T U R R A X UTL 1000/10 Serial No.: 06-5819 PERATING INSTRUCTIONS Reg. No. 4343-01...
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Page 3: Table Of Contents
® -WERKE Table of Contents For your safety....................4 1.1 General dangers .....................4 1.2 Definition......................4 1.3 Use as directed....................4 1.4 Protective measures ..................5 1.4.1 Safety obligations on the part of the operator..........5 1.4.2 Specific safety information and symbols used.........6 1.4.3 General safety information ..............7 1.4.4 Basic safety information during normal operation........8 1.4.5 Basic safety measures for maintenance and repairs.......9 1.4.6 Working on electrical equipment ............11... - Page 4 12 Assembly drawing..................38 12.1 Detail 1 of assembly drawing ..............39 12.2 Detail 2 of assembly drawing ..............40 13 Dimension sheet.....................41 14 Troubles/Causes and troubleshooting ............42 15 EC Declaration of Conformity................45 16 IKA address overview ..................46 Annexe: • Documentation shrink disc TLK 603...
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Page 6: For Your Safety
® -WERKE 1 For your safety 1.1 General dangers The machine itself is not dangerous if directions for its use are followed. However, if this machine is modified or combined with other machines dangers may arise that could not be foreseen by the manufacturer. We must point out that the user must follow the guidelines for the given workplace when using this machine. -
Page 7: Protective Measures
® -WERKE 1.4 Protective measures 1.4.1 Safety obligations on the part of the operator The machine (including the subassemblies) has been designed and built in accor- dance with a tolerance analysis and careful selection of the harmonized standards to be observed as well as other technical specifications. It thus corresponds to the state of the art and provides maximum safety during operation. -
Page 8: Specific Safety Information And Symbols Used
® -WERKE 1.4.2 Specific safety information and symbols used The following operating instructions contain specific safety information referring to the unavoidable remaining risks when operating and maintaining the machine. These risks involve dangers for • persons • the product and machine •... -
Page 9: General Safety Information
® -WERKE 1.4.3 General safety information Modifications to the system and its components 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. -
Page 10: Basic Safety Information During Normal Operation
® -WERKE 1.4.4 Basic safety information during normal operation Before switching on the machine, obtain information on how to behave in the event of abnormal occurrences. Danger The machine may only be operated by appropriately trained and authorised persons familiar with the operat- ing instructions (and those for the subassemblies) and capable of working according to them. -
Page 11: Basic Safety Measures For Maintenance And Repairs
® -WERKE 1.4.5 Basic safety measures for maintenance and repairs The machine may only be maintained by qualified and authorised personnel under observation of the safety information and who are familiar with the operating in- structions (and those for the subassemblies) and are capable of working according to them. - Page 12 ® -WERKE Dispose of environmentally hazardous lubricating, cool- ing or cleaning agents appropriately. Danger Following all assembly work, free movement of the drive shaft must be ensured by manual turning before switch- ing on the drive. Secure the drive against unauthorised activation.
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Page 13: Working On Electrical Equipment
® -WERKE 1.4.6 Working on electrical equipment Check whether the motor is running in the correct direc- tion (arrow on the ventilator unit) by switching it on and off briefly. Info The device connection must comply with VDE stan- dards. Ensure that the motor voltage for the motor con- nection and the mains voltage are identical. -
Page 14: Working On The Barrier System
® -WERKE 1.4.7 Working on the barrier system The machine may not be operated (not even for short periods) without an intact barrier system. Otherwise the mechanical seal may be destroyed. Note Maintenance and repair work on the barrier system may only be carried out by personnel specially trained for this purpose. -
Page 15: Observing Environmental Protection Guidelines
® -WERKE 1.4.8 Observing environmental protection guidelines The statutory obligations governing the avoidance of waste and the correct recycling/disposal of materials must be observed during all work on or with the ma- chine. In particular during installation, repair and maintenance Danger work, water-polluting substances such as lubricating grease and oil, hydraulic oil, cooling agents, cleaning... -
Page 16: Description
® -WERKE 2 Description Make sure that the type designation and the serial number on the front page corre- spond with the machine type plate. If these data do not agree please contact us immediately. ® The ULTRA-TURRAX is a high quality, multipurpose mixing machine particularly suited for the continual mixing of solids and liquids. -
Page 17: Construction Of The Ultra-Turrax
® -WERKE ® 2.1 Construction of the ULTRA-TURRAX 2.1.1 Sealing cartridge Into the pump casing (710) a sealing cartridge (500) is integrated. This sealing car- tridge essentially consists of a sealing casing, a double-acting mechanical seal and a drive sleeve. The seal has following characteristics: The slip ring on the product side has few fissures or only very small fissures projecting into the product space, thus reducing product collection in fissures, and has spring elements that do not contact the product. -
Page 18: Specification Sheet
® -WERKE 3 Specification sheet Rotor speed (60 Hz) 3600 rpm Circumferential speed on the outside of the rotor : 19 m/s Rotor speed (50 Hz) 3000 rpm Circumferential speed on the outside of the rotor : 16.1 m/s Max. permissible product temperature 120 °... - Page 19 ® -WERKE 3.1 Locking pressure system Max Betriebsdruck: 16 bar Behältervolumen: Nutzinhalt: 2,5 l zul. Betriebstemperatur: 200° C Kühlfläche: 0,1 m Kühlschlangeninhalt: 0,25 l Gewicht : 7 kg...
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Page 20: Dimensions And Weight
® -WERKE 3.2 Barrier system Max. operating pressure: 16 bar Container volume: Useful capacity: 2,5 l Permissible operating temperature: 200° C Cooling surface: 0.1 m Cooling coil capacity: 0.25 l Weight : 7 kg 3.3 Dimensions and weight: See also chapter 14 Height: approx. -
Page 21: Installation
® -WERKE 4 Installation 4.1 Securing the machine The machine can be set up using the optional base frame. 4.2 Connecting product lines The machine has 2 connections for products lines and one cleaning connection. The horizontal connection (704) for the introduction of material. The vertical connection for the product discharge is located in the pump casing (710). - Page 22 Depending on the application it is possible to use other media. However, never use explosive, combustible, oxidising or toxic media. Please contact IKA. In case of locking liquid viscosity values > 5mm /s always use an additional circula-...
- Page 23 ® -WERKE 4.3.4 Pressure in the barrier system The pressure in the barrier system should be approx. 2 bar higher than the operating pressure in the pump chamber. The pressure is generated/reduced by filling / releas- ing compressed air or inert gas (e.g. nitrogen, argon) at the pressure valve. Both the pressure (→...
- Page 24 ® -WERKE 4.3.5 Cooling The barrier reservoir has two 1/4“ pipe sockets for cooling which open into an interior pipe coil. The cooling liquid can be discharged into any direction. At barrier temperatures exceeding 65° C, there is a dan- ger of burning at the barrier reservoir and the supply pipes.
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Page 25: Power Supply
® -WERKE 4.4 Power supply The device connection must comply with VDE stan- dards. Ensure that the motor voltage for the motor con- nection and the mains voltage are identical. The motor voltage is indicated on the motor rating plate or in the technical data sheet. -
Page 26: Operating Mechanisms On The Machine
® -WERKE Operating mechanisms on the machine This machine is delivered without a control panel ® 6 Placing the ULTRA-TURRAX in operation See also chapter 12 6.1 Connecting the machine After setting up the machine on a safe surface the machine is connected to the power supply. -
Page 27: Information For Working With Product
® -WERKE 6.3 Information for working with product ® The ULTRA-TURRAX -machine is especially designed for the dispersing of fluids. Successful operation of the machine, however, requires observing the following: 6.3.1 Periphery ® The ULTRA-TURRAX has it own pressure head, but it does not automatically suck in the mix components. -
Page 28: Adjusting The Output Quantity
® -WERKE The mechanical seal may not run dry, i.e. the machine must always be filled with sufficient medium to provide lubrication and cooling of the sliding rings. Otherwise, the mechanical seal might be damaged. Caution Therefore, is recommended to equip the machine with a flow monitor, when the ma- chine is not attended during operation. -
Page 29: Servicing
® -WERKE 7 Servicing 7.1 The mechanical seal The mechanical seal can have an outstanding service life, if: • Allowable pressure conditions are maintained • Sufficient cooling and moisturizing are maintained • The proper combination of materials are used The slip rings are subject to natural wear. The wear is dependent upon: •... -
Page 30: The Mixing Tool
® -WERKE 7.2 The mixing tool The high speed mixing tool and especially the fine toothed dispersion level is sensi- tive to foreign objects. Therefore absolutely avoid allowing objects such as, screws, stones and welding beads etc. to enter the machine. Be especially careful to avoid this when adding mixing components. -
Page 31: Assembly And Disassembly
® -WERKE 8 Assembly and disassembly See also chapter 12. Following all assembly work, free movement of the drive shaft must be ensured by manual turning before switch- ing on the drive. Secure the drive against unauthorised activation. Info Switch off the power supply at the main switch prior to maintenance or repair work and secure with a padlock. -
Page 32: Mixing Tool
® -WERKE 8.2 Mixing tool 8.2.1 Removing the mixing tool • Loosen feed lines • Loosen 4 cap nuts (720) and remove • Pull up the inlet flange (704) sidewards • Pull up the stator (1006) • Loosen screws (424) and replace protection plate (422) •... -
Page 33: Mechanical Seal Cartridge
® -WERKE 8.3 Mechanical seal cartridge 8.3.1 Disassembly of the mechanical seal cartridge • Disassemble the inlet flange and the mixing tools as shown in 8.2.1 • Mount the 4 assembly safety clamps for the sealing cartridge with hexagon head bolts SW3 (see chapter 13) •... -
Page 34: Motor Shaft
® -WERKE 8.4 Motor shaft 8.4.1 Removing the motor shaft • Removal of casing parts, mixing tools, sealing cartridge was described in 8.2.1 and 8.3.1 • Loosen hexagon socket head screw (421) • Remove lantern (428) sidewards • Loosen set screw (410) at the centrifuge disk •... -
Page 35: Ordering Spare Parts
® -WERKE 9 Ordering spare parts To order spare parts please use the form below. This allows us to process your or- der quickly. Do the following: 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. - Page 36 ® -WERKE...
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Page 37: Parts List Ultra-Turrax Utl 1000/10
® -WERKE ® 10 Parts list ULTRA-TURRAX UTL 1000/10 Parts list U079105 Pos. Quant. Order no. Designation U080670 Three-phase a.c. motor 7,5 U077995 Base frame S103057 Buffer D 75x25 S102327 Hexagon head cap nut DIN 934 M12-A4 U079536 Baseboard S100714 Hexagon head cap screw DIN 933 M10x60-A2 S100716 Hexagon head cap screw DIN 933 M12x25-A2... - Page 38 ® -WERKE Pos. Quant. Order no. Designation S092772 Pressure screw 1004 S094908 Rotor 4M 1006 S094907 Stator 4M with 3.1B certificate 1202 S055888 Arrow plate (On the motor hood) 1204 S055891 Type plate ULTRA-TURRAX 1206 U079406 Type plate (Logo) UTL 1000/10 1302 S101531 Straight screw connection GE 12-PLR-1.4571...
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Page 39: Seal Materials And Alternative
® -WERKE 11 Seal materials and alternative Double-acting face seal with cartridge construction form. The standard material com- bination used is: stationary rotating seal O-rings springs housing seal face face parts material material (silicon car- (silicon car- (FPM) (Hastelloy® (CrNiMo- bide) bide) C 4) -
Page 40: Assembly Drawing
® -WERKE 12 Assembly drawing... -
Page 41: Detail 1 Of Assembly Drawing
® -WERKE 12.1 Detail 1 of assembly drawing... -
Page 42: Detail 2 Of Assembly Drawing
® -WERKE 12.2 Detail 2 of assembly drawing only with option base frame... -
Page 43: Dimension Sheet
® -WERKE 13 Dimension sheet... -
Page 44: Troubles/Causes And Troubleshooting
® -WERKE 14 Troubles/Causes and troubleshooting Cause Troubleshooting • Failure of the mains voltage Check the voltage supply by authorised personnel • Voltage supply off Plug in the plug, main switch ON • Motor only runs with 2 phases Check electrical connec- tion •... - Page 45 ® -WERKE Cause Troubleshooting • Supply line or mixing chamber Remove deposits in the clogged up machine and/or pipework • trapped air in the mixing Vent device and/or suc- chamber or suction pipe, par- tion pipe ticularly in case of horizontal suction pipe •...
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Page 47: Ec Declaration Of Conformity
® -WERKE 15 EC Declaration of Conformity EC Declaration of Conformity as defined by EC Machinery Directive 98/37/EC, Appendix II A ® Herewith we, - 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 requirements stipulated by the EC directives. -
Page 48: Ika Address Overview
MASCHINENBAU PROCESSING EQUIPMENT PROCESSING EQUIPMENT ® ® ® WERKE GmbH & Co. KG IKA WORKS, INC. WORKS (Asia) Sdn Bhd Janke & Kunkel- Str. 10 2635 NORTH CHASE PKWY, SE No. 17 & 19, Jalan PJU 3/50 D 79219 Staufen...
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