IKA Works: LABOR-PILOT 2000/4

IKA WORKS
Operating Instructions
LABOR-PILOT 2000/4
Serial Number:
IKA WORKS
TABLE OF CONTENTS
1 EC DECLARATION OF CONFORMITY .............................................................................................................5
2 FOR YOUR SAFETY..............................................................................................................................................7

2.1 GENERAL DANGERS ................................................................................................................................................7
2.2 DEFINITION ............................................................................................................................................................7
2.3 CORRECT USE .........................................................................................................................................................7
2.4 SAFETY PRECAUTIONS.............................................................................................................................................7
2.4.1 User's duty of care ........................................................................................................................................7
2.4.2 Special safety information and symbols used .................................................................................................8
2.4.3 General safety information............................................................................................................................9
2.4.4 Basic safety precautions during normal operation.........................................................................................9
2.4.5 Basic safety precautions during service and maintenance ...........................................................................11
2.4.6 Work on the electrical equipment ................................................................................................................12
2.4.7 Observe the environmental protection regulations.......................................................................................12
2.5 OTHER DANGERS ..................................................................................................................................................12
3 DESCRIPTION OF THE LABOR-PILOT 2000/4..............................................................................................14
3.1 BEFORE USING THE LABOR-PILOT ......................................................................................................................14
3.2 DESCRIPTION OF THE DEVICE .................................................................................................................................14
3.2.1 Description of the main unit and of the attached notes ................................................................................14
3.2.2 Electronic control .......................................................................................................................................15
3.3 PRINCIPLE OF OPERATION ......................................................................................................................................16
3.3.1 Modular design ...........................................................................................................................................16
3.3.2 Principle of operation of the basic device....................................................................................................17
3.3.3 Principle of operation of the Module DISPAX-REACTOR® DR...................................................................19
3.3.4 Principle of operation of the MHD module..................................................................................................20
3.3.5 Principle of operation of the Colloid mill MK module .................................................................................21
3.4 DIMENSIONS.........................................................................................................................................................23
3.4.1 Figure 1 Dimension sheet............................................................................................................................23
3.4.4 Dimension table ..........................................................................................................................................25
4 SPECIFICATIONS................................................................................................................................................26
4.1 LABOR-PILOT ...................................................................................................................................................26
4.2 ELECTRICAL SYSTEM ............................................................................................................................................27
4.2.1 Motor:.........................................................................................................................................................27
4.2.2 LABOR-PILOT CONTROLLER...................................................................................................................28
4.2.3 Power supply / Cable ..................................................................................................................................29
4.3 DIMENSIONS AND WEIGHTS OF LABOR-PILOT 2000/4:.........................................................................................29
5 INSTALLATION...................................................................................................................................................30
5.1 MOUNTING AND ALIGNMENT OF THE MACHINE .......................................................................................................30
5.2 PRODUCT CONNECTIONS .......................................................................................................................................30
5.2.1 Connection size at the inlet and outlet socket ..............................................................................................30
5.2.2 Operation using flow-through processes......................................................................................................31
Accessories for operation using circulation processes .............................................................................................32
5.2.3.1 Circulation pipe...................................................................................................................................................33
5.2.3.2 Telescopic stand leg ............................................................................................................................................33
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5.2.4 Connection on the suction side ................................................................................................................... 34

5.2.5 Connection on the delivery side.................................................................................................................. 35
5.2.6 Connection of the MHD module ................................................................................................................. 36
5.3 HEATING/COOLING CONNECTIONS ........................................................................................................................ 37
5.4 VOLTAGE SUPPLY................................................................................................................................................. 38
6 OPERATION ........................................................................................................................................................ 39
6.1 OPERATING DEVICES OF THE MACHINE WITHOUT LABOR-PILOT CONTROLLER ................................................ 39
6.1.1 Operating element ...................................................................................................................................... 39
6.1.2 Functions.........................................................................................................Error! Bookmark not defined.
6.1.3 Operation ........................................................................................................Error! Bookmark not defined.
6.2 OPERATION OF THE LABOR-PILOT CONTROLLER................................................................................................ 40
6.2.1 Abbreviations: ............................................................................................................................................ 40
6.2.2 Design:....................................................................................................................................................... 40
6.2.3 Controller speed range:.............................................................................................................................. 40
6.2.4 Installation ................................................................................................................................................. 41
6.2.5 Wiring Diagram.......................................................................................................................................... 42
6.2.6 Functions: .................................................................................................................................................. 44
6.2.7 Operating elements: ................................................................................................................................... 44
6.2.8 Operation of the controller:........................................................................................................................ 44
6.2.9 View of HMI display:.................................................................................................................................. 45
6.2.10 HMI function keys:................................................................................................................................. 46
6.2.11 LEDs of the HMI:................................................................................................................................... 47
6.2.12 View of all display pages:....................................................................................................................... 48
7 COMMISSIONING OF THE LABOR-PILOT 2000/4........................................................................................ 54
7.1 CONNECTING THE MACHINE...............................................................................ERROR! BOOKMARK NOT DEFINED.
7.2 BRIEF TEST .......................................................................................................................................................... 55
7.3 INFORMATION ON WORKING WITH PRODUCT .......................................................................................................... 56
7.3.1 Peripheral equipment ................................................................................................................................. 56
7.3.1.1 General .............................................................................................................................................................. 56
7.3.1.2 MHD module ..................................................................................................................................................... 56
7.3.2 Adaptation possibilities of the LABOR-PILOT to the process...................................................................... 57
7.3.2.1 General .............................................................................................................................................................. 57
7.3.2.2 Grinding gap adjustment MK module ................................................................................................................. 58
7.3.3 Starting the machine................................................................................................................................... 59
7.3.4 Calculation of the throughput rate.............................................................................................................. 60
7.3.5 Operation using circulation processes with the hopper ............................................................................... 61
8 ASSEMBLY AND DISASSEMBLY..................................................................................................................... 64
8.1 FITTING TOOLS .................................................................................................................................................... 65
8.2 DISASSEMBLY OF GENERATOR AND ROTARY SHAFT SEAL ........................................................................................ 66
8.3 ASSEMBLY OF ROTARY SHAFT SEAL ....................................................................................................................... 71
9 MODIFICATION OF THE BASIC DEVICE TO OTHER MODULES ............................................................ 73
9.1 GENERAL NOTES .................................................................................................................................................. 73
9.2 PREPARATORY WORK: .......................................................................................................................................... 73
9.3 MODIFICATION TO DR MODULE ............................................................................................................................ 74
9.3.1 Disassembly of pump unit ........................................................................................................................... 74
9.3.2 Assembly of DR module .............................................................................................................................. 74
9.4 MODIFICATION TO MHD MODULE ........................................................................................................................ 79
9.4.1 Disassembly of pump unit ........................................................................................................................... 79
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9.4.2 Assembly of MHD module ...........................................................................................................................79

9.5 MODIFICATION TO MK MODULE............................................................................................................................84
9.5.1 Disassembly of pump unit............................................................................................................................84
9.5.2 Assembly of MK module ..............................................................................................................................84
10 MAINTENANCE...................................................................................................................................................89
10.1 THE ROTARY SHAFT SEAL ..................................................................................................................................89
10.2 THE GENERATORS .............................................................................................................................................90
10.3 THE BEARINGS..................................................................................................................................................90
10.4 DRIVE SHAFT ....................................................................................................................................................90
10.4.1 Disassembly of the drive shaft.................................................................................................................90
10.4.2 Assembly of drive shaft ...........................................................................................................................90
10.5 TENSIONING THE V-BELT ..................................................................................................................................91
11 TROUBLES/CAUSES AND TROUBLESHOOTING .........................................................................................93
12 ORDERING SPARE PARTS ................................................................................................................................95
13 SPARE PARTS LIST AND DRAWINGS:............................................................................................................95

13.1 MACHINE SPARE PARTS LIST ..............................................................................................................................95
13.2 FIGURE 3 MACHINE SPARE PARTS DRAWING .......................................................................................................98
13.2.1 Figure 4 Detail of figure 3 ......................................................................................................................99
13.2.2 Figure 5 Detail of figure 3 .................................................................................................................... 100
13.3 ........................................................................................................................................................................... 101
13.4 - DR MODULE SPARE PARTS LIST AND DRAWING .............................................................................................. 101
13.5 - MHD MODULE SPARE PARTS LIST AND DRAWING .......................................................................................... 103
13.6 - MK MODULE SPARE PARTS LIST AND DRAWING ............................................................................................. 105
14 APPENDIX .......................................................................................................................................................... 106
14.1 SCALE-UP ...................................................................................................................................................... 106
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1 EC Declaration of Conformity
EC Declaration of Conformity
as defined by EC Machinery Directive 98/37/EG, 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 requirements stipu-
lated 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: LABOR-PILOT

Machine type: 2000/4
Serial no.:
Year of construction: 2002
Relevant EC directives: 98/37/EEC, Appendix II A

Applied harmonised standards: EN 292-1
EN 292-2
EN 294
EN 349
EN 414
EN 418
Applied national standards

and technical specifications: DIN 42673
DIN 42677
DIN 11851
DIN 50049
VDE 0530 Part 5/ IEC 34 Part 5
VDE 0100/0113
Date 14/03/2001
Manufacturer's signature:
Information on the undersigned: Assistant Manager
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2 For your safety
2.1 General dangers

Used correctly, the machine itself does not pose any danger. Installation or combination with other
machinery can, however, present dangers that are unintentional on the part of the manufacturer. We
would like to draw your attention to the fact that the user must observe work area guidelines when
operating the machine.
2.2 Definition
The terms used in these operating instructions correspond to the
EN 292-1 / 2.
The in-company technical documentation also corresponds to the
EN 292-1 / 2.
2.3 Correct use

In order to prevent damage to persons or machinery, the machine may only be operated in accor-
dance with its intended use.
The LABOR-PILOT 2000/4 has a modular design, i.e. the machine can be operated as basic device
or can be turned into differently operating devices using modules.
The basic device LABOR-PILOT 2000/4 as well as the modules DISPAX-REACTOR® DR and Colloid
mill MK are designed for dispersing mixtures during the liquid, pumpable phase.
Dispersions include the area of emulsions (liquid/liquid), suspensions (liquid/solid), and aerosols
(gaseous/liquid).
The device 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 ma-
chine prior to feeding in substances.
The LABOR-PILOT including the MHD module is designed for mixing and homogenising liquid sub-
stances with powdery substances.
2.4 Safety precautions
2.4.1 User's duty of care

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
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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 par-
ticular the functional reliability of the safety equipment is checked at regular intervals
• required personal protective equipment for operating, maintenance, and repair personnel is avail-
able and will be worn
• the operating instructions are always legible and complete at the site of operation of the machine
• the machine is exclusively operated, maintained, and repaired by qualified and authorised per-
sonnel
• this personnel, at regular intervals, shall receive instruction regarding all questions concerning
work safety and environmental protection and that they are familiar with the operating instructions
and in particular with the included safety information
• all safety signs and warnings attached to the machine itself will not be removed and made illegi-
ble
2.4.2 Special safety information and symbols used

The following operating instructions give special safety information in order to point to residual risks
involved when operating or maintaining the machine that can not be avoided. These residual risks
include dangers for
• persons
• product and machine
• environment
The symbols used in these operating instructions are mainly meant to draw the attention to the safety
information!
This symbol indicates that above all dangers for persons must be
expected.
(Danger of life, risk of injury)
Danger
This symbol indicates that above all dangers for machine, material,
and environment must be expected.
Attention
The most important aim of the safety information is to prevent personal injury.
If the warning triangle with the “Danger” caption is placed in front of a safety instruction, this means
that dangers for machine, material, and environment can not be excluded.
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If the warning triangle with the “Attention” caption is placed in front of a safety instruction, this means
that dangers for persons are, however, not to be expected.
The respective symbol used can not replace the text of the safety instruction. Therefore, always read
the text completely!
This symbol does not point to safety information, but to in-

formation for a better understanding of the sequences of ma-
chine operation.
Note
2.4.3 General safety information
Modifications of the system and parts of it are only allowed with

written approval of IKA. Otherwise the warranty and the declaration
of conformity will become void!
Danger
If connected to the power supply, the system is live. This voltage
may have highly dangerous effects when being touched.
Danger
Subject to technical modifications.
Note
2.4.4 Basic safety precautions during normal operation
Before switching the machine on, inform yourselves about the cor-
rect behaviour in case of failures!
Danger
The machine may only be operated by trained and authorised per-
sons who are familiar with the operating instructions (also of the
subassemblies) and who are able to follow these instructions!
Danger
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Replace all hose lines at regular intervals as a preventive mainte-

nance measure, even if no damages can be recognised!
(Observe the manufacturers' indications!)
Danger
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
Danger
Make sure that an additional stirrer in the hopper is adjusted to a
low speed before switching it on. In case of too high speed adjust-
ments some liquid may spurt out of the hopper in dependence on
the filling level when operating with open hopper. Particularly dur-
Danger ing operation with installed wiping stirrer the lowest speed must be
adjusted before operation.
The machine is not appropriate for the exclusive supply and treat-
ment of pure dry substances. This may cause serious damages of
the device
Note
When changing the dispersing material, it should be checked if the

material of the rotary shaft seal and the O-rings is still suitable. It
may be necessary to replace the parts against parts made of other
materials.
Note In case of doubt, please contact your supplier or the IKA plants
directly.
After the assembly work is completed and before the drive is
switched on, check the clearance of the machine's drive shaft by
manually turning it.
In doing so, protect the drive against inadvertent starting!
Note
The machine is not suitable for processing abrasive substances.

Abrasive substances cause early wear particularly of the rotary
shaft seal which may lead to undesired product leakage.
Note
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2.4.5 Basic safety precautions during service and maintenance
The machine may only be maintained by qualified and

authorised persons observing the safety information and who
are familiar with the operating instructions (also of the subas-
semblies) and who are able to follow these instructions!
Danger
Before any maintenance and repair work switch off the main
switch of the power supply and lock it with a padlock! The key
of this lock must be with the person carrying out the mainte-
nance or repair work!
Danger
Before any maintenance and repair work ensure that all parts
of the machine that must possibly be touched have cooled
down to ambient temperature!
Danger
Before carrying out any maintenance or repair work close the
access to the work area of the machine for unauthorised per-
sons! Attach or erect a sign that draws the attention to the
maintenance or repair work!
Danger
Observe the inspection and maintenance intervals prescribed
by the operating instructions!
Observe the maintenance and repair instructions of the sub-
assemblies included in these operating instructions!
Danger
Ensure proper disposal of environmentally hazardous lubri-
cating, cooling or cleaning agents!
Danger
The pressing screw (730) should be screwed hand-tight and
then be tightened with a tightening torque of approx. 17 Nm. It
is recommended to additionally lock the thread with a liquid
but with normal tools detachable screw locking (e.g.
LOCTITE).
Note
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2.4.6 Work on the electrical equipment
Connection of the device must correspond to VDE standards.

The connection to the power supply must be realised in ac-
cordance with the indicated data, such as rated voltage, rated
frequency, rated current, and maximum fuse protection. The
motor rating can be found on the motor rating plate or the
technical data sheet.
Attention
• 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!
Danger • Immediately replace damaged lines/cables!
• Always keep the control cabinet closed! Access only for
authorised persons with key/tool!
• Never clean control cabinets and other housings of the
electrical equipment using a water hose!
2.4.7 Observe the environmental protection regulations
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
Danger 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!
2.5 Other dangers

The machine has been designed in such a way that neither the machine itself nor its accessories
may present any danger to persons, products or the environment. The operating instructions have
been drawn up in such a way that no dangers should arise if the warnings and maintenance guide-
lines are observed.
It is, however, impossible to rule out danger sources attributable to human error.
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No other risks are to be anticipated upon proper use of the device and consideration of the recom-
mendations and guidelines in accordance with the regulations governing the prevention of accidents
and the employer's liability insurance associations.
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3 Description of the LABOR-PILOT 2000/4
3.1 Before using the LABOR-PILOT
After unpacking the device, check the following items, and the number and completeness in accor-
dance with your order.
• Does the type designation and serial number on the rating plate correspond to your order ?
• Has the LABOR-PILOT 2000/4 been damaged during transport, have some screws loosened ?
Should the indicated data not correspond to your order, please contact us immediately.
3.2 Description of the device
3.2.1 Description of the main unit and of the attached notes
Motor rating
plate
Inlet flange
Rating plate
Rotation
Mixing head arrow
Motor
Outlet flange
Base plate
Lantern with
flange gasket
During cleaning of the machine, please make sure not to destroy signs and labels using solvents or
to make them illegible.
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Motor
The transmission of power from the motor (100) to the drive shaft (426) and the dispersing tools
(904) is performed by a sufficiently dimensioned belt drive. The drive shaft is separately supported in
the lantern. The motor is mounted on a movable base plate (210) so that the V-belt can be ten-
sioned.
Base plate
The base plate ensures that the device is set up safely on the floor. In order to achieve an isolation
between machine and floor the equipment is installed on adjustable rubber feet.
Lantern with flange gasket
In order to seal the pump housing (710) against the drive shaft (426), a rotary shaft seal (501) is in-
tegrated in the flange gasket (500).
Mixing head
The mixing head consists of the inlet socket ( 704 ), the pump housing ( 710 ) as well as a mixing
tool. Depending on the current module, this mixing tool can be replaced by other mixing tools. Ac-
cording to the module, the mixing heads have different designs. Each module is equipped with inde-
pendent mixing tools and chambers.
In case of the basic device the stationary part of the mixing tool, i.e. the stator, is double-walled and
simultaneously designed as housing of the dispersion chamber. All other modules, such as DISPAX-
REACTOR® DR, MHD, colloid mill MK, are as well equipped with a standard double casing.
The double casing is suited for heating or cooling of the dispersion housing. Appropriate tempering
media can be fed in or discharged at the two connections G 1/8“. Appropriate tempering media are
e.g. water, heat-transfer oil, steam.
3.2.2 Electronic control
The electronic control of the basic device is realised by a switch mounted on the motor. The switch
includes a motor protection switch for overload monitoring, an undervoltage release for protection
against restarting after a voltage breakdown and the emergency stop switch.
The optional controller is a separate device being connected to the motor using a 1.5 m long cable.
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3.3 Principle of operation
3.3.1 Modular design
The basic version of the LABOR-PILOT is a single-stage, high-quality, and multipurpose dispersion
device for continuous dispersion of liquids.
Inlet
Outlet
Generator
The LABOR-PILOT has a modular design. In its basic version, the LABOR-PILOT will be delivered
ready for connection. Optionally, it can be converted into the following devices using the modules
listed below:
-
Module DISPAX-REACTOR® DR :
Extension stage for the three-stage dispersing ma-
chine
- MHD module : Extension stage for mixing and dispersion of powdery
substances in liquids
- Colloid mill MK module : Extension stage for the colloid mill
The conversion is described in chapter 9. The conversion from the basic version into one of the
modules is mainly limited to changing the product-contacting parts. The following parts are equal for
all modules and need not be modified:
• The complete drive with the motor, the belt drive, and the base plate
• The lantern with the shaft, the shaft bearing, and the rotary shaft seal
• The product outlet case with the outlet socket
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3.3.2 Principle of operation of the basic device

The basic device is a single-stage high-performance instrument for continuous dispersion of liquids.
Single-stage dispersing instruments are also known at IKA Plants under the trade name ULTRA-
TURRAX® INLINE or abbreviated UTL. Thus, the LABOR-PILOT is especially suitable for scale-up
purposes to larger production machines particularly of the Inline 2000 series.
The dispersing action is based on the rotor-stator principle, which means that a high-speed rotor with
very narrow slots rotates in a stator. This produces high shearing energies between rotor and stator.
The system consisting of rotor and stator is also called generator. With the help of differently fine-
toothed generators the device can be adapted to the respective dispersing task. The different gen-
erators must always be used in pairs. Rotors and stators with differently fine-toothed generators must
not be combined with one another, as this might damage the device.
The device 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.
A standard three-phase a.c. motor powers the drive at 3000 rpm and protection category IP55. The
transmission ratio of the belt drive increases the speed of the rotor shaft to 7900 rpm. The circumfer-
ential speed at the periphery of the rotor given this speed is 23 m/s.
Optionally, the speed of the LABOR-PILOT can be adjusted with the LABOR-PILOT CONTROLLER.
The adjustable speed ranges from 3160 rpm to 13750 rpm. The maximum circumferential speed at
the periphery of the rotor is reached at the highest speed and is approx. 40 m/s. As the circumferen-
tial speed of the rotor has a decisive influence on the dispersion result, the LABOR-PILOT
CONTROLLER offers an excellent possibility to adapt the device to the processing requirements.
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Generator – pumping stage Generator, coarse-

2P toothed 2G
Generator, medium- Generator, fine-

toothed 4M toothed 6F
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3.3.3 Principle of operation of the Module DISPAX-REACTOR® DR

The LABOR-PILOT with the module DISPAX-REACTOR in contrast to the basic device is a three-
stage dispersing instrument with three generators being installed one after the other. This multistage
arrangement of rotor-stator-systems makes it possible to answer maximum requirements on homog-
enisation and dispersion of emulsions and suspensions. With the help of differently fine-toothed
generators the device can be adapted to the respective dispersing task. The generators can be com-
bined in any order, but the coarser-toothed generators should be installed towards the inlet.
certain lift. The lift depends on the tool used and the speed. The three-stage device achieves a
higher lift than the single-stage basic device.
Like the basic device, the speed of LABOR-PILOT with the module DISPAX-REACTOR can option-
ally be adjusted using the LABOR-PILOT CONTROLLER. The adjustable speed ranges from 3160
rpm to 13750 rpm. The maximum circumferential speed at the periphery of the rotor is reached at the
highest speed and is approx. 40 m/s. As the circumferential speed of the rotor has a decisive influ-
ence on the dispersion result, the LABOR-PILOT CONTROLLER offers an excellent possibility to
adapt the device to the processing requirements.
In case of certain generator combinations, particularly in case of the combination with three fine-
toothed generators 6F6F6F, and in dependence on the product to be mixed, the power limit can be
reached at very high speeds. Nevertheless, the rated current of the motor should not be exceeded
for a longer period. If necessary, the speed must be reduced to such an extent that the rated current
of the motor will just not be exceeded. The rated current can be read at the display of the LABOR-
PILOT CONTROLLER. In case of an overload of the motor, it will be switched off by activating a
thermal motor protection.
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3.3.4 Principle of operation of the MHD module
The LABOR-PILOT with the MHD module is a high-quality, multipurpose mixing device for continuous
mixing of solid substances with liquids. Both the solid and the liquid component must be proportioned
into the device at the respective inlet socket. In the device itself, the components are intimately
mixed, dispersed or homogenised and are discharged from the device via an outlet socket.
The controlled feeding of the liquid and the solid component results in a final product with propor-
tional quantities, the exactness depending on the feeding devices. Feeding can be realised using
e.g. the following devices:
Proportioning device Remark

Proportioning of the solid Volumetric proportioning screw Reduced expenditure, varying
component proportioning accuracy
Gravimetric ratio weigher High expenditure, high propor-
tioning accuracy
Proportioning of the liq- Eccentric screw pump Simple, not suitable for all prod-
uid component ucts
Rotary-piston pump, gear High expenditure, suitable for
pump most products
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.
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 pos-
sible. Their task is to bring the fed mixing components in contact with each other, to mix them inti-
mately, and to discharge the mixed product from the machine.
The tools used differ in dependence on the mixing zone. They are mounted on the drive shaft one
after the other and are fixed by the topmost tool. This topmost tool is designed as a screw. The
screw is located in the area of the solids inlet and has the following tasks:
• Take the solid substance in the premixing chamber
• Clear the solids inlet area from possible caking
• Cut the "wet" premixing area off of the "dry" solids area
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. Depending on the application, this can be de-
signed purely as a pump wheel or an additional dispersing stage together with a stator can be in-
stalled. The types 2P, 2G, 4M can be used as generators. The generator 6F can not be used for the
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MHD module.
Premixing chamber
In the premixing chamber, the components to be mixed get in touch with each other. It consists of a
casing with a central liquid connection and an exchangeable injector jacket. It is fixed by the solids
inlet socket. The liquid component is fed into the central connection under pressure, distributes in the
space between casing and injector jacket and will then be injected into the premixing area via the
openings of the injector jacket.
Pump housing
The pump housing is located below the premixing chamber. A stator and thus an additional dispers-
ing stage can be installed optionally here. The product to be mixed is radially accelerated by the ro-
tating impeller and discharged via the outlet socket.
Like the basic device, the speed of the LABOR-PILOT with the MHD module can optionally be ad-
justed using the LABOR-PILOT CONTROLLER. The adjustable speed ranges from 3160 rpm to
13750 rpm. The maximum circumferential speed at the periphery of the rotor is reached at the high-
est speed and is approx. 40 m/s. As the circumferential speed of the rotor has a decisive influence
on the dispersion result, the LABOR-PILOT CONTROLLER offers an excellent possibility to adapt
the device to the processing requirements. Operation with the MHD module should first be started at
the standard speed of 7900 rpm, and all further optimisations should be realised on the basis of this
speed.
3.3.5 Principle of operation of the Colloid mill MK module
The LABOR-PILOT with the colloid mill MK module is a high-performance colloid mill incl. a grinding
gear, which, like the basic device, is designed according to the rotor-stator-principle. However, the
grinding gear design differs considerably from that of the basic device. The grinding gap between
rotor and stator has a conical design and allows a continuous adjustment of the grinding gap by
means of axially displacing the stator. This grinding gap adjustment enables an optimum adaptation
of the device 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 up 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.
certain lift. The lift depends on the adjusted grinding gap and the speed.
Like the basic device, the speed of the LABOR-PILOT with the colloid mill MK module can optionally
be adjusted using the LABOR-PILOT CONTROLLER. The adjustable speed ranges from 3160 rpm
to 13750 rpm. The maximum circumferential speed at the periphery of the rotor is reached at the
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highest speed and is approx. 40 m/s. As the circumferential speed of the rotor influences the milling
result, the LABOR-PILOT CONTROLLER offers an additional possibility to adapt the device to the
processing requirements. Operation with the colloid mill MK module should first be started at the
standard speed of 7900 rpm, and all further optimisations should be realised on the basis of this
speed.
In case of certain products or product characteristics, e.g. high viscosity, especially the power limit of
the device can be reached at very high speeds. Nevertheless, the rated current of the motor should
not be exceeded for a longer period. If necessary, the speed must be reduced to such an extent that
the rated current of the motor will just not be exceeded. The rated current can be read at the display
of the LABOR-PILOT CONTROLLER. In case of an overload of the motor, it will be switched off by
activating a thermal motor protection.
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3.4 Dimensions
3.4.1 Figure 1 Dimension sheet

LABOR-PILOT 2000/4 with motor protection switch
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LABOR-PILOT 2000/4 for operation with LABOR-PILOT CONTROLLER
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Basic device DR module MHD module MK module
A C A
3.4.4 Dimension table

See also figures 1, 2, and 3
Modules A B C H
Inlet Outlet Liquid on Height
in mm
Basic device LABOR-PILOT 2000/4 DN 25 DN 15 - 305

Module DISPAX-REACTOR® DR DN 25 DN 15 - 343
MHD module DN 50 DN 15 DN 15 347
Colloid mill MK module DN 25 DN 15 - 343
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4 Specifications
4.1 LABOR-PILOT
Operation as basic device without speed regulation

Rotor speed (60 Hz) : 7900 rpm
Sound pressure level : 73 dB(A)
Operation with speed regulation at the LABOR-PILOT CONTROLLER

Rotor speed (24 – 105 Hz) : 3160 – 13750 rpm
Max. sound pressure level : 83 dB(A)
Other general data

Max. permissible product temperature : 120 °C
Max. permissible operating overpressure : 3 bar
Max. permissible temperature of double casing : 120 °C
Max. permissible operating overpressure of double : 2 bar
casing
Max. throughput rates

The values apply to the standard speed of 7900 rpm, water 20 °C, the throughput rates increase almost linearly with the
speed
Basic device, single-stage, generators 2G, 4M, 6F : approx. 350 liters/h

Basic device, single-stage, generator 2P (pump : approx. 3500 liters/h
stage)
Module DISPAX-REACTOR  DR : approx. 350 liters/h
Colloid mill MK module : approx. 300 liters/h
MHD module, total quantity : approx. 100 liters/h
Materials
Product-contacting parts Stainless steel 1.4571 / 316 Ti
Lantern, frame Stainless steel
Rotary shaft seal PTFE Compound
Elastomeric working chamber (only standard version) FPM (Viton)
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4.2 Electrical system
4.2.1 Motor:
General
Operating voltage (depending on the version) : 3 x 240/460V / N / PE
Frequency : 60 Hz
Capacity : 2HP
Motor speed (60 Hz) : 3600 rpm
Protection category : IP 55
Insulation class : F
Explosion protection : none
with thermocouple, suitable for frequency converter : 24 - 105 Hz
operation
Mains power supply

Supply line : Supplied by customer
Mains voltage : 3 x 230 V + PE / ±10 %
Mains frequency : 60 Hz
Max. distortion of the supply voltage : ± 2.0 % of the rated supply voltage
Power factor (400 V) / cos. ϕ : 0.9 / 1.0 given rated load
Switching actions at the supply input : 2 x / min
Max. fuse protection : 16 A, class B characteristics, circuit-
breaker for overcurrent protection (IEC898)
Connection cable:
Motor cable : 3 m, oil-resistant cable with integrated
thermistor line, connected ready for use
Environment:
Housing : Stainless steel
Protection category : Front IP 55, back IP 53
Dimensions : W x H x D = 210 x 380 x 300 mm
Ambient temperature : 10 – 35 °C
Max. relative humidity : 5 % - 85 % during operation
Atmosphere : Must be free from aggressive liquids, parti-
cles, and gases which might damage or
impair the electronic parts
Max. height above sea level : 1000 m
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EMC:
Interference voltage (conducted emission at the : DIN EN 50 081-1 : EN 55011-1 B
mains connection)
Interfering field strength (emission level) : DIN EN 50 081-1 : EN 55011-1 B
Immunity DIN EN 50 081-2 : EN 61000-4-
2/3/4/5/6
Speed regulation:
Rated speed of motor : 7900 rpm (60 Hz)
Speed control range : 3160 – 13750 rpm (24 – 105 Hz)
Increment : 106.2 rpm (0.67 Hz)
Motor current measurement:

Motor current measuring range : 0.00 - 6.00 A
Accuracy of motor current measurement : +/-
Temperature measurement:
Temperature measuring range : 0 – 200 °C
Accuracy of temperature measurement : +/- 1 °C
Timer function:
Time range : 0 – 120 min
Discrimination : 1 min
4.2.2 LABOR-PILOT CONTROLLER

Operating voltage (depending on the version) : 3 x 220-240V / N / PE
Frequency : 60 Hz
Power output : 2HP
Ambient temperature : 10 - 35 °C
Output frequency range : 24 - 105 Hz
Temperature indicator : 0 - 200 °C
Explosion protection : none
The LABOR-PILOT CONTROLLER consists of a stainless steel housing complete with frequency
converter, speed indicator, temperature indicator, timer, clear text display with language selection,
adapter DN 15 with thermosensor Pt 100 at the product outlet
à refer to special description in chapter 6.2 !
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4.2.3 Power supply / Cable

The device will be delivered without an input power connection. It is the customer's responsibility to
have a qualified electrician make the input power connection. It is recommended that a 4-conductor
cable, of correct wire AWG, be connected through the liquid tight hub, located on the rear panel, into
the 3-pole fuseblock. On the input side, the device is connected for a clockwise rotating field as a
standard. à refer to brief test!
4.3 Dimensions and weights of LABOR-PILOT 2000/4:

See also figure 1 to 3
These indications relate to a standard device with a 2HP drive motor.
Height : approx. 319 mm

Length : approx. 464 mm
Width : approx. 250 mm
Weight of LABOR-PILOT 2000/4 : approx. 36 kg
Weight of LABOR-PILOT CONTROLLER approx. 17 kg
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5 Installation
5.1 Mounting and alignment of the machine

The machine can be mounted freely with the base plate.
The machine must be mounted on even ground. The machine base must be aligned horizontally us-
ing a spirit level along its longitudinal and transverse axis. For levelling, the rubber feet (item 204) at
the base plate can be height-adjusted. The rubber feet are self-locking and must not be additionally
secured after adjustment.
5.2 Product connections

The LABOR-PILOT 2000/4 including the modules DISPAX-REACTOR® DR and Colloid mill MK can
either be operated using circulation or flow-through processes.
The corresponding accessories for the respective operating modes can be supplied by IKA Plants.
5.2.1 Connection size at the inlet and outlet socket

The LABOR-PILOT is equipped with screwed pipe connections acc. to DIN 11851 (milk pipe fitting)
for product supply and discharge. The nominal widths of the basic device and the individual modules
can be found in the following table:
Inlet Inlet socket Inlet socket

Modules Outlet socket
socket Powder Liquid
Basic device LABOR-PILOT 2000/4 DN 25 - - DN 15
Module DISPAX-REACTOR® DR DN 25 - - DN 15
MHD module - DN 50 DN 15 DN 15
Colloid mill MK module DN 25 - - DN 15
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5.2.2 Operation using flow-through processes
Inlet
Outlet
If the hose connectors, which can be delivered as accessories, are screwed to the inlet and outlet, it
is possible to connect corresponding hoses for product supply and discharge. Pay attention that the
hoses are securely clamped at the hose connectors. Exclusively use hoses that are compatible with
the product and show a sufficient pressure, temperature, and media resistance.
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5.2.3 Accessories for operation using circulation processes
Stirrer
RW 28
basic
Wiping
stirrer
Telescopic
stand Hopper
Straight- Circulating
way ball elbow
valve
3-way tap
cock
Hose
connector /
Box nut
Temperatur
e sensor
Laboratory Pt100
Pilot 2000/4
The accessories, which can be delivered by the IKA Plants, can be mounted to the LABOR-PILOT
according to the dimension drawing. Instead of the wiping stirrer shown it is also possible to use
other stirring tools, such as propeller stirrer, turbine stirrer etc., depending on the product quality
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5.2.3.1 Circulation pipe

As far as the circulating elbow is concerned pay attention that, when using the wiping stirrer, the
lower edge of the outlet is at least 5 mm above the upper edge of the wiping stirrer. For this a straight
extension is delivered which must be mounted between the 3-way tap cock and the outlet elbow.
If the wiping stirrer is not used or another stirring tool is used, the intermediate piece is not neces-
sary. However, always pay attention that the stirring tool can definitely not touch the outlet elbow.
5.2.3.2 Telescopic stand leg
The telescopic stand leg is fixed at the base of the LABOR-PILOT using a clamping piece:
Clamping piece
Lever-type
handle
Fixing lugs
• The telescopic leg must be securely screwed to the clamping piece.

• Push the clamping piece with the two fixing lugs into the groove on the motor base plate and into
the groove on the bottom of the plate.
• Align the clamping piece vertically using the adjusting screw
• Firmly tighten the clamping lever
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• Check that the fastening is free from play and secure
5.2.4 Connection on the suction side
If the accessories provided by the IKA Plants are not used or the machine is permanently piped, pay
attention that the pipework does not exert any additional load on the machine.
The following items have to be observed:

• The suction side should be designed as a free inlet if possible. The piping should be as short as
possible and fitted with few elbows. Provide suitable supports and flexible connections in order to
keep the machine free of loads exerted by the pipework.
• If the suction side is not designed as a free inlet, provide a prefilling unit.
• Carefully realise the connections on the suction side and avoid leakage.
• Avoid unfavourable conditions on the suction side, e.g. long piping, high suction height etc.
• Absolutely avoid any inclusion of air. The supply line must be laid rising towards the machine,
and falling in case of inlet.
• Do not dimension the suction pipe smaller than the suction connection.
Optimum conditions Unsuitable conditions
Inclusion of air
Inclusion of air
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5.2.5 Connection on the delivery side

If the accessories provided by the IKA Plants are not used or the machine is permanently piped, pay
attention to the following.
• Keep the machine free of loads exerted by the pipework. Provide suitable supports and flexible
connections for this.
• If the pipework is too long, the resistance of the pipework increases and the performance data of
the machine change. The pipework diameter should be selected considering the resistance of the
pipework.
• To be able to adjust the delivery volume later, it is advisable to install a control valve on the deliv-
ery side, e.g. a ball valve, flap valve.
• A pressure gauge preceding the control valve as near as possible to the outlet is useful.
• In case of long horizontal delivery lines, a ventilation possibility should be provided.
• The installation of non-return devices and shut-off elements is especially useful with long pipe-
work.
• Before commissioning, containers, pipework, and connections must be thoroughly cleaned and
rinsed, so that during operation no welding beads, scale or other impurities can loosen and dam-
age the machine or other system parts.
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5.2.6 Connection of the MHD module
The machine has three connections for product pipes.

The vertical connecting sleeve for the solids supply is located in the upper section of the machine.
Here, the connection of a volumetric or gravimetric proportioning screw must be realised.
The central connection for the liquid mixing component supply is located in the casing. The connec-
tion 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
"5.2.4 Connection on the suction side".
The connection for the product discharge is located in the pump housing. When installing pipework,
observe the items mentioned under "5.2.5 Connection on the delivery side".
Volumetric
feeder
Installation example LABOR-PILOT with MHD module storage
hopper
Powder inlet Electronic

control
Supply
Outlet
Eccentric
screw pump
with variable
speed gear to
control the
liquid
component
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5.3 Heating/Cooling connections
The basic device as well as all other modules are additionally equipped with heating/cooling connec-
tions in the form of female threads G 1/8. One connection each is located in the inlet cover and one
in the outlet chamber. They are protected with a standard closing plug, and in case of need they can
be connected to suitable heating or cooling devices via hose lines using suitable screwed pipe con-
nections. Appropriate tempering media are e.g. water, heat-transfer oil, and steam.
Outlet
heating/cooling
connection Inlet
heating/cooling
connection
If the working chamber is brought to a specified temperature,

above 65 °C the danger of burns exists at the non-insulated work-
ing chamber and the supply lines. In this case the hot parts must
be provided with a touch guard by the user.
Danger
The permissible temperature range in the double casing is 10 up to
120 °C. The permissible pressure of 2 bar must not be exceeded.
Note
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5.4 Voltage supply

Refer to Appendix Electrical description
The electrical connection of the device must be made in ac-

cordance with local and building codes and comply with all
applicable regulatory standards.
The incoming electrical power must be compatible with the
motor data, such as rated voltage, rated frequency, rated cur-
rent, and maximum fuse protection. The motor rating can be
Attention found on the motor rating plate, technical data sheet or con-
sult the manufacturer.
• Use only a qualified electrician to carry out repair work on
the electrical equipment of the machine!
authorized persons with key/tool!
• Never clean control cabinets and other electrical equip-
ment using a water hose!
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6 Operation
6.1 Operating the machine without LABOR-PILOT CONTROLLER
6.1.1 Operating controls

It is the customer’s responsibility to provide the electrical controls to operate the machine. At a mini-
mum an on/off switch with emergency-stop function should be connected in the incoming power to
turn the drive motor on and off. Have a qualified electrician determine the proper controls and wire
needed to meet all national, local and building codes. Electrical safety must be followed to keep the
user safe.
6.1.2 Optional controls

To vary the speed of the motor a Variable Frequency Drive (VFD) may be purchased and installed.
Always follow the manufacturers instructions for proper installation.
-or-
Purchase a Process Controller from IKA Works to control the machine as described in the following
section.
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6.2 Operation of the LABOR-PILOT Controller
After unpacking the device, check the following items, and the number and completeness in accor-
dance with your order.
• Does the type designation and serial number on the rating plate correspond to your order?
• Has the LABOR-PILOT 2000/4 been damaged during transport or have some screws loosened?
Should the indicated data not correspond to your order, please contact us immediately.
6.2.1 Abbreviations:
The following abbreviations are used throughout the text:
HMI = Controls and displays (Human Machine Interface)

FC = Frequency converter (controls the motor)
6.2.2 Design:
The controller is housed in a separate control cabinet, which will be installed separately. The inter-
connection lines between controller and drive motor are hardwired to the machine. The temperature
measuring line can be plugged in at the controller.
The controller utilizes a VFD (Variable Frequency Drive), which provides adjustable speed control of
the Labor Pilot®.
6.2.3 Controller speed range:

The controller can be adjusted from 24Hz to 105Hz for a shaft speed range of 3160RPM to
13750RPM.
The following chart specifies the speed range to operate each module. It is recommended that you
operate within these specifications. Exceeding these ranges may result in mechanical failure.
Module SHAFT/RPM Hz MOTOR/RPM M/sec.

MK 3160-7900 24-60 1440-3600 8.5-23
MHD 3160-7900 24-60 1440-3600 8.5-23
UTL 3160-7900 24-60 1440-3600 8.5-23
DR 3160-7900 24-60 1440-3600 8.5-23
DRS 3160-13750 24-105 1440-6300 8.5-40
All IKA® 2000 machines are designed to operate at rotor tip speed of 23m/sec at 60Hz from this
size through all production models. The speed can be reduced if process conditions require it.
The DRS is the only exception. It is designed to operate at a rotor tip speed of 40 m/sec when
maximum energy input is required.
Please consult IKA with any questions regarding the application.
Note: The speed value shown on HMI display indicates the shaft speed.
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6.2.4 Installation
The electrical connection of the device must be made in ac-
cordance with local and building codes and comply with all
applicable regulatory standards.
The incoming electrical power must be compatible with the
motor data, such as rated voltage, rated frequency, rated cur-
rent, and maximum fuse protection. The motor rating can be
Attention found on the motor rating plate, technical data sheet or con-
sult the manufacturer.
• Use only a qualified electrician to carry out repair work on
the electrical equipment of the machine!
authorized persons with key/tool!
• Never clean control cabinets and other electrical equip-
ment using a water hose!
Power Supply Connection

After determining the proper wiring requirements, run the incoming power cable through the seal-tight
fitting located on the rear panel of the controller. Connect the corresponding leads to L1/L2/L3 ter-
minals of the fuseblock. (refer to wiring diagram) It will be necessary to remove the fuse covers to
access the terminals. Connect the ground wire to the ground stud located near the main switch
making sure to allow enough lead length for door to open and close properly. After connecting all
wires, replace the fuse covers back on to the fuses.
Labor-Pilot Motor Connection

The cable exiting the controller box will be connected to the labor-pilot motor. The cable contains 6
wires. After determining the correct motor configuration, connect the wire labelled U1 to L1, V1 to L2,
W1 to L3, and ground wire to motor ground. Wires labelled 5 and 6 are used to connect to the motor
thermal overload sensor, if it has one. If the motor does not have an internal thermal sensing device,
then connect wires 5 and 6 together.
Note: Once the Labor-Pilot and Controller are connected and verified, then test run the motor very
briefly to verify the motor is rotating in the correct direction. If it is not rotating in the right direction,
then change the direction of rotation by switching two phases of the incoming power at the fuseblock
terminals or switching two phases at the motor terminals.
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6.2.5 Wiring Diagram
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6.2.6 Functions:
The LABOR-PILOT Controller has the following functions:
• Clear text display with language selection

• Variable speed adjustment
• Displays for: • Set point value of speed
• Actual value of speed
• Actual value of motor current
• Actual value of product temperature
• Set point value of operating time in timer mode
• Actual value of remaining time in timer mode
• Actual value of operating hours
• Timer mode
• Error messages as text display
6.2.7 Operating elements:

The following operating elements are available and can be found on the front of the controller:
Operating element Function

• Main switch • Switching the power supply on and off
• Emergency stop
• Controls and displays (HMI) • Switching the drive on and off
• Set point assignment
• Actual indication
• Malfunction indication
6.2.8 Operation of the controller:
On-off switching:
With the 1 button the drive is switched on, with the 0 button it is switched off again. The LED above
the 1 button indicates the operation of the drive.
Speed regulation:
The ⇑ and ⇓ buttons are used for speed regulation. This depends on the selected display. Please
find information on the matter in the descriptions of the displays.
Time function:
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The Timer button is used to switch the Time function on and off. If the Timer function is switched on,
the LED above the Timer button indicates this.
During the time function, the drive runs for the set period and is then switched off.
For starting, the 1 button must also be actuated and can be stopped again using the 0 button before
the time has elapsed.
If the drive is stopped before the remaining time has elapsed, it will automatically be set to 0. When
starting in timer mode, the remaining time is automatically set to the period for which the drive still
has to run.
Automatic switching-off:
In case of each switching-on of the main switch or of failures of the FC or the motor, the drive will be
automatically switched off and must be switched on manually again.
6.2.9 View of HMI display:
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6.2.10 HMI function keys:
Keys Page Function LED

all Switching on the drive Drive on
all Switching off the drive no function
TIMER all Switching on the time function: Time func-

If the time function is switched on, the drive tion on/off
must be switched on first. It will then run for the
indicated period and will then automatically
switch off
no function Time runs
all Deleting failures -
all Paging to the previous display -
all Paging to the following display -
Increasing the value (with auto-repeat function) -
Decreasing the value (with auto-repeat func- -

tion)
all Only for setup function, password-protected -
Call and quit info display -
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6.2.11 LEDs of the HMI:
Name/symbol Colour State Signification

OFF No hardware problem detected
red FLASHING Battery low (this instrument has no battery)
ON HMI hardware error
OFF No button pressed
green
ON With each keystroke (visual feedback)
OFF No alarms
red FLASHING Alarm requires acknowledgement (not used)
ON Alarm active
OFF no function
red FLASHING no function
ON no function
FLASHING Communication error (with the frequency con-
verter)
green
ON Communication OK (with the frequency con-
verter)
OFF HMI hardware error
green
ON Device in operation
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6.2.12 View of all display pages:

Display page 1:
s p e e d X X X X X 1 / m i n
t e m p . X X ° C
This is the start page after switching on; the speed can be adjusted here, too.
Display line Display contents Unit
1 Actual speed [rpm]
2 Actual temperature [°C]
Keys Function LED

Switching on the drive Drive on
Switching off the drive no function
TIMER Switching the time function on/off Time function

on/off
(flashes)
Deleting failures -
no function -
Paging to display 2 -
Increasing the speed -

Decreasing the speed -
Setup function, password-protected -

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Display page 2:
s e t v a l . X X X X X 1 / m i n
c u r r e n t X . X X A
n
1 Set speed [rpm]
2 Actual current consumption [A]
Keys Function LED


on/off
(flashes)
Deleting failures -
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Display page 3:
n o m . - t i m e X X X m i n
r e s t - t i m e X X X m i n
During timer operation, the set point value is set and the remaining time is displayed on this page.

1 Setpoint time [min]
2 Actual remaining time (after timer [min]
start)
Keys Function LED


on/off
(flashes)
Deleting failures -
Increasing the time -
Decreasing the time -

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Display page 4:
i n v e r t e r X X X X X . X h
m o t o r r X X X X X . X h
On this page, the operating hours of the frequency converter and the motor are displayed.

1 Actual value of operating hours of con- [h]
verter
2 Actual value of operating hours of motor [h]
Keys Function LED

1 Switching on the drive Drive on
0 Switching off the drive no function

on/off
(flashes)
Deleting failures -

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Display page 5:
A d j u s t m e n t c o n t r a s t
d i s p l a y :
The readability of the display strongly depends on the angle of view to the display. This can be bal-
anced by adjusting the contrast of the display on this page.
Keys Function LED

1 Switching on the drive Drive on
0 Switching off the drive no function

on/off
(flashes)
Deleting failures -
Increasing the contrast -
Decreasing the contrast -

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Display page 6:
S e l e c t l a n g u a g e :
1 = e n g l i s h
On this page, the operator language is selected.

At present, the following languages can be selected:
No. Display Language

1 English English
2 Deutsch German
3 Francais French
Display line Display contents Language

2 Selected language
Keys Function LED


on/off
(flashes)
Deleting failures -
Select next language -
Select previous language -

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7 Commissioning of the LABOR-PILOT 2000/4

For the following description refer to the figure
7.1 Start-up
After proper installation of the machine on a safe ground and proper installation of the controller, the
device is ready for start-up. Please read the following sections to understand how your specific ma-
chine will work. It is important that user fully understands how the machine will work for safe opera-
tion.
Controls and
displays
Main switch
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7.2 Brief test

The following should be checked during a brief test run:
- Direction of rotation of the motor
- Unusual, mechanical noise
The device may only run dry for a short period, otherwise the rotary
shaft seal on the product side will be destroyed.
Attention
In case of the colloid mill module, observe a sufficient running
clearance between the grinding gears. Otherwise the machine may
be damaged.
Attention
Check by briefly switching-on if the motor turns in the marked di-
rection (arrow on the blower housing). If the motor turns in the
wrong direction, the input rotating field in the connecting plug must
be changed by an authorised person by means of shifting two
phases.
Attention
Never reach into the mixing chamber while the motor is running.
The rotating mixing tools present the risk of injury.
Danger
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7.3 Information on working with product

The LABOR-PILOT has been particularly designed for processing liquids. With the MHD module, the
LABOR-PILOT can also mix powdery solids with liquids and homogenise them. However, for suc-
cessful operation with the machine, the following must be observed:
7.3.1 Peripheral equipment
7.3.1.1 General
The LABOR-PILOT 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 set grinding gap.
A precondition for a proper function and a constant mixing performance is that the product to be
mixed is supplied uniformly e.g. via the optional feeding hopper (does not apply to the MHD module).
Viscous product to be mixed, which does not flow independently into the machine via a hopper, may
require to be fed into the LABOR-PILOT using a pump. To feed the liquid component or to circulate
the product to be mixed, pumps working according to the displacement principle, such as rotary pis-
ton, gear or eccentric screw pumps, proved successful.
They have a relatively stable characteristic and are generally driven by variable speed geared mo-
tors.
When using a pump, pay attention that the permissible operating pressure of 3 bar is not exceeded.
7.3.1.2 MHD module

In case of the MHD module, both the solid and the liquid component must be proportioned into the
device at the respective inlet socket. In the device itself, the components are mixed or homogenised
and discharged from the device via an outlet socket.
The controlled feeding of the liquid and the solid component results in a final product with propor-
tional quantities, the exactness depending on the feeding devices. Feeding can be realised using
e.g. the following devices:
Proportioning device Remark

Proportioning of the solid Volumetric proportioning screw Reduced expenditure, varying
component proportioning accuracy
Gravimetric ratio weigher High expenditure, high propor-
tioning accuracy
Proportioning of the liq- Eccentric screw pump Simple, not suitable for all prod-
uid component ucts
Rotary-piston pump, gear High expenditure, suitable for
pump most products
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.
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7.3.2 Adaptation possibilities of the LABOR-PILOT to the process
7.3.2.1 General
The LABOR-PILOT 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.
The generator 6F is not suitable for operation with the MHD module
and must not be installed there.
With the MHD module, the standard generator to be used is the 2P

generator (pump rotor combined with a single-rim stator). Alterna-
Note tively, the generators 2G and 4M can be used.
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7.3.2.2 Grinding gap adjustment MK module

The colloid mill MK module can be adapted to the process using the continuous grinding gap adjust-
ment. The grinding gap is adjusted manually by turning the adjusting ring being located on the out-
side of the housing. In dependence on the angle of rotation the following grinding gap is obtained.
Table: Radial gap adjustment
Indicated Rotations of the ad- Radial gap in

angle in ° justing ring mm
0 0 0
90 1/4 0,104
180 1/2 0,208
270 3/4 0,312
360 1 0,416
450 1 1/4 0,520
540 1 1/2 0,624
630 1 3/4 0,728
720 2 0,832
810 2 1/4 0,936
900 2 1/2 1,040
990 2 3/4 1,144
1080 3 1,247
1170 3 1/4 1,351
1260 3 1/2 1,455
1350 3 3/4 1,559
1440 4 1,663
1530 4 1/4 1,767
1620 4 1/2 1,871
1710 4 3/4 1,975
1800 5 2,079
Adjusting the grinding gap
Zero position
During initial start-up, after a disassembly as well as after a longer operating period, the grinding gap
adjustment must be checked and, if necessary, be corrected. For that purpose, first loosen the lock
nuts (736) at the star knob screws (734) of the adjusting ring (716). Subsequently, turn the adjusting
ring clockwise until it reaches a tangible stop. The radial 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 run-
ning clearance must be adjusted.
Running clearance
The adjusting ring (716) is now turned anticlockwise until the desired clearance according to the ra-
dial gap adjustment table is reached. For this, the adjusting ring must be turned (clockwise to the left)
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by at least 180° in order to ensure a sufficiently safe running clearance between rotor and stator.
Subsequently, check by manually turning the shaft if the rotor can be rotated freely. This can be
done with the help of the delivered open-end wrench (OW10) which is placed on the upper shaft nut
and is used to turn the shaft clockwise. Subsequently, the lock nuts (736) at the star knob screws
(734) of the adjusting ring (716) must be tightened.
7.3.3 Starting the machine

Fundamentally, it must be mentioned that the LABOR-PILOT is a flow machine. As a result of the
high speed, a minimum liquid content of the product to be mixed is required for the function of the
machine. The possible mixing ratio is strongly dependent on the product as with a too high solids
content the limit of the permissible product viscosities may be reached.
The machine is not appropriate for the exclusive supply and treat-
ment of pure dry substances. This may cause serious damages of
the device.
Note
The machine is not suitable for processing abrasive substances.
Abrasive substances cause early wear particularly of the rotary
shaft seal which may lead to undesired product leakage.
Note
Therefore it is recommended to provide a flow monitor when using the machine in unsupervised
systems which monitors the liquid supply and immediately switches the LABOR-PILOT off if no liquid
is supplied.
Moreover, this basic rule influences the sequence of starting and stopping the machine. The se-
quence should be as follows:
The instrument may only be switched on after radial gap adjust-

ment.
Attention
Starting the machine
1. Preselect the maximum standard speed of 7900 rpm (only for operation at the LABOR-PILOT
CONTROLLER)
2. Start the LABOR-PILOT motor
3. Start the liquid component (pump)
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4. Start the powdery component (only with MHD module)

5. If necessary, increase speed slowly
Stopping the machine
1. Stop the powder supply (only with MHD module)

2. Stop the liquid supply, if necessary rinse briefly first
3. Stop the LABOR-PILOT motor
The device may only run dry for a few seconds, otherwise the ro-
tary shaft seal on the product side will be destroyed.
Attention
The instrument may only be operated for a short moment with
closed valve on the discharge side. During longer operation, the
frictional heat of the rotary shaft seal is no longer dissipated, which
means that it heats inadmissibly and may be destroyed.
Attention
After having used the machine it must be cleaned. This is particu-
larly important in case of hardening product to be mixed, as the
function of the rotary shaft seal on the product side may be af-
fected or it may be destroyed.
Attention
For operation at the LABOR-PILOT CONTROLLER, the machine
should be started at a maximum speed of 7900 rpm. If necessary,
decrease the speed slowly.
Note
7.3.4 Calculation of the throughput rate

In dependence on the tool, the application of the LABOR-PILOT is possible in a wide range of
throughputs. The actually possible maximum throughput and thus the calculation of the supplied
product flow depends on the following factors:
• Viscosity of the product to be mixed
• Swelling properties of the product to be mixed
• Solids concentration of the product to be mixed
• Lift at the outlet
• Dispersing, grinding or mixing tool
• Grinding gap (Colloid mill MK module)
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Fundamentally, it applies that per unit of time only as much liquid and solids can be supplied that can
be mixed and discharged by the LABOR-PILOT.
Moreover, it must be stated that generally the mixing result will be best if achieved close to the
maximum possible throughput. In case of low throughputs, the result and a uniform liquid flow can
also be improved by means of an “artificial load”, e.g. a throttle at the product discharge.
If no practical values are available, a test must be carried out to settle the question which product-
specific maximum throughput can be realised.
If the LABOR-PILOT is operated at the LABOR-PILOT CONTROLLER, the standard speed of 7900
rpm must be adjusted as output speed. This applies to the basic device as well as to all other mod-
ules. All further optimisations should be started from this speed. Fundamentally, the speed adjust-
ment should not be higher than required by the process. An increased speed causes stronger wear
particularly of the rotary shaft seal on the product side.
7.3.5 Operation using circulation processes with the hopper

If the basic device, the module DISPAX-REACTOR® DR or the colloid mill module are operated with
the optional hopper, the circulation pipe, the RW 28 basic stirrer or the wiping stirrer, the following
must be observed:
Particularly when using the wiping stirrer the lowest speed of the
stirring motor must be adjusted during start-up and before switch-
ing on. A too high speed adjustment presents the danger that
product to be mixed may spurt out of the hopper.
Danger
In case of prolonged circulation of the product to be mixed using
the LABOR-PILOT, the product to be mixed may strongly heat par-
ticularly at high speeds and with a high power consumption. Ob-
serve the temperature development in the container and at the cir-
Danger culation pipe and, if necessary, connect a cooling unit. In case of
temperatures above 65 °C at the outer casing, provide a suitable
touch guard, otherwise there is the danger of burns.
When working with the LABOR-PILOT at the open hopper, wear
corresponding protective clothing as product may squirt out of the
hopper both with the stirring motor switched on and switched off.
Danger
Never reach into the container or the stirring shaft incl. stirrer while
the stirring motor is running.
Danger
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Never reach into the open hopper when working with the LABOR-
PILOT.
Danger
Procedure
• The straight-way ball valve on the inlet side of the LABOR-PILOT serves as a barrier between the
hopper contents and the LABOR-PILOT. While the LABOR-PILOT is running, the straight-way
ball valve must be opened to prevent dry running.
• The 3-way tap cock on the outlet side should only be operated in the following two switching po-
sitions, if possible:
• Outlet open, connection to the outlet socket (see figure 1), product will be discharged
while the machine is running. Collect the discharged product in a suitable receiver or use
a suitable discharge pipe.
• Outlet open, connection to the circulating elbow (see figure 2), product will be circulated in
the hopper while the machine is running.
Figure 1 Figure 2
Valve lever
top
Valve lever
left
• With closed outlet, the LABOR-PILOT may only be operated for a short moment, as the product
in the outlet chamber may very strongly heat.
When opening the 3-way tap cock towards the outlet socket while
the machine is running pay attention to the delivery pressure which
might cause the product to come out very fast when opening the
cock. With open outlet wear corresponding protective clothing.
Danger
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8 Assembly and disassembly

In the following chapter the most important assembly work is described.
After the assembly work is completed and before the drive is

switched on, check the clearance of the machine's drive shaft by
manually turning it.In doing so, protect the drive against inadver-
tent starting!
Note
Before any maintenance and repair work switch off the main switch
of the power supply and lock it with a padlock! The key of this lock
must be with the person carrying out the maintenance or repair
work!
Danger
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8.1 Fitting tools

For assembly and disassembly it is advisable to use the delivered tool set:
Item Quan- Unit Order no. Designation

10 1 pc. 1056917 Tool bag
20 1 pc. 1056918 Open-end wrench OW 6/7
30 2 pc. 1056919 Open-end wrench OW 10/13
40 1 pc. 1056921 Hexagon socket screw key OW 5
50 1 pc. 1056922 Pin d=6 mm
60 1 pc. 1056923 Slotted screw driver size 4.5 mm
70 1 pc. 1056924 Articulated hook wrench size 35-60
80 1 pc. 1056361 Mounting sleeve for rotary shaft seal
90 1 pc. 1057205 Circlip pliers size S1
10
60
30
70
50
90
20
40
80
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8.2 Disassembly of generator and rotary shaft seal

• With an easy later disassembly in mind we recommend to slightly coat the hubs of rotors, dis-
tance sleeves, and O-rings with a suitable grease before assembly.
• During assembly pay attention that the O-rings between the individual parts must lie correctly in
the groove when fitting parts together.
434
720
- Detach the product pipes

- Unscrew and remove 2 cap nuts
(720)
704 - Remove inlet socket (704) upwards.

Remove O-rings (608, 610).
- Remove stator (904) upwards

904
- Unscrew hexagon socket screw plug

(434) anticlockwise using hexagon
socket screw key OW 5 and remove
it
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Locking
pin
732
730
- Put locking pin ∅6 through the bore
of the lantern and into the bore of
the shaft (426)
Unscrew pressing nut (730) anticlock-

730 wise using the open-end wrench OW10
- Remove pressing nut (730)
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- Pull off 2 distance sleeves (732) upwards, see

next two figures
710
732
904 - Pull off rotor (904)
905
- Pull off distance washer (905) up-

wards
- Remove pump housing (710) up-

wards. Remove O-rings (608, 610).
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- Take off both O-rings (614)

500
- Remove flange gasket (500) up-
wards
502
- Remove circlip (502) and force ro-
tary shaft seal (501) out of the
flange gasket using the thumb or a
bolt
501
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8.3 Assembly of rotary shaft seal

• Assembly is carried out in reverse order as described in 9.3 Disassembly of rotary shaft seal.
• With an easy later disassembly in mind we recommend to slightly coat the hubs of rotors and
distance sleeves with a suitable grease before assembly.
• Keep the sealing surfaces free from dust and impurities. Pay attention to the correct installation
position of the parts. In particular
• Press the new rotary shaft seal (501) into the flange gasket (500) using the rotary shaft seal
mounting sleeve.
• Do not forget the two O-rings (614) at the stud bolts as well as the total of four O-rings between
the housing parts (608, 610). The O-rings at the stud bolts (614) as well as the two exterior O-
rings (608) between the housing parts exclusively seal the heating jacket. If the heating jacket is
not used, these O-rings need not be mounted.
• see also 8.4 Disassembly and assembly of O-ring seals
Mounting sleeve
for rotary shaft
seal
501
• During assembly pay attention that the O-rings between the individual parts must lie correctly in
the groove when fitting parts together. The O-rings must not be twisted or dented by components.
The rotary shaft seal must fit uniformly and under no circum-
stances at an angle into the flange gasket. Otherwise the tightness
of the ring is not ensured.
Note
Pay attention to the correct installation position of the ring. The
sealing lip must be installed so that it points towards the product
side. Only this way can it seal the machine against pressure
Note
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The rotary shaft seal must not be damaged during assembly. Even
smaller defects of the sealing lip result in leakage.
Note
The pressing screw (730) should be screwed hand-tight and then
be tightened with a tightening torque of approx. 17 Nm. It is rec-
ommended to additionally lock the thread with a liquid but with
normal tools detachable screw locking (e.g. LOCTITE).
Note
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9 Modification of the basic device to other modules
9.1 General notes

Before any modification switch off the main switch of the
power supply and lock it with a padlock! The key of this lock
must be with the person carrying out the maintenance or re-
pair work!
Danger
The user has to ensure that the modification and assembly work may only be carried out by author-
ised and qualified experts who have thoroughly read the operating instructions and are sufficiently
informed.
9.2 Preparatory work:
• Disconnect the current supply

• Dismount accessories, such as shut-off valves, hoppers etc.
• Detach piping from the inlet and outlet side
• Motor and lantern remain on the base plate
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9.3 Modification to DR module
9.3.1 Disassembly of pump unit
722
500
9.3.2 Assembly of DR module
722 - Disassembly is carried out in the

order as described in 8.2 Disassem-
bly of rotary shaft seal.
- Unscrew and remove 2 stud bolts
(722, short)
Rotary shaft
seal pointing
upwards - Screw in 2 stud bolts (722, long)
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- Put on flange gasket (500)
614
- Put on 2 O-rings (614) (sealing of

heating jacket)
- Put on pump housing (710)

- Insert two O-rings (608, 610) into
710 the chamber, on the outside to seal
the double casing (can be dropped if
the double casing is not used), on
the inside to seal the mixing cham-
ber
- Put on distance washer (905)
905
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1004 904
- Put on rotor 6F (1004)
- Put on stator 6F (1004)

1004 - Insert two O-rings (608, 610) into
the stator, on the outside to seal the
double casing (can be dropped if the
double casing is not used), on the
inside to seal the mixing chamber
- Put on rotor 4M (904)

904
- Put on stator 4M (904)

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804
Locking
pin
- Put on rotor 2G (804)
- Put on stator 2G (804)

804 double casing (can be dropped if the
- Tighten pressing screw (730) manu-

ally

the shaft (426)
730
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730 434
- Tighten the pressing screw (730)

clockwise using the open-end
wrench OW10
The pressing screw (730) should be screwed hand-tight and then
be tightened with a tightening torque of approx. 17 Nm. It is
recommended to additionally lock the thread with a liquid but with
Note
- Put on inlet socket (704)

704 - Insert one O-ring (624) each into the
cap nut, if necessary grease it
slightly so that it sticks to the groove.
The O-rings can be dropped if the
double casing is not used.
720 - Tighten 2 cap nuts (720)
- Tighten hexagon socket screw plug

(434) clockwise using a hexagon
socket screw key OW 5
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9.4 Modification to MHD module
- Disassembly is carried out in the order as de-

scribed in 8.2 Disassembly of rotary shaft seal.
722 - Unscrew and remove 2 stud bolts

(722, short)
9.4.2 Assembly of MHD module
722
- Screw in 2 stud bolts (722, long)
500
Rotary shaft
seal pointing
upwards
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614
- Put on 2 O-rings (614)
710 - Put on pump housing (710)

the chamber, on the outside to seal
ber
- Put on distance washer (905)

905
- Put on pump wheel 2P (1104)

1104
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Locking
806 pin
centre
position
804
lower
position
- Put on 2 mixing tools (804) at the

top and at the bottom and 1 mixing
804 tool (806) in the centre position. The
upper three mixing tools must be put on so
position that adjacent stirrer blades are stag-
gered. For this the position of the
keyway is designed differently
802
- Screw on feeding screw (802)

the shaft (426)
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802 - Tighten the feeding screw (802)

clockwise using the open-end
wrench OW10
-
The feeding screw (802) should be screwed hand-tight and then

be tightened with a tightening torque of approx. 17 Nm. It is
recommended to additionally lock the thread with a liquid but with
Note
- Put on stator 2G (1104)


ber
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434
602
902
- Place injector casing (902)

- Insert O-ring (602) into the injector
casing from above
- Put on inlet socket (704)

704 - Insert one O-ring (624) each into the
cap nut, if necessary grease it
720
- Tighten 2 cap nuts (720)

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9.5 Modification to MK module

- Disassembly is carried out in the order as de-
scribed in 8.2 Disassembly of rotary shaft seal.
722
- Unscrew and remove 2 stud bolts

(722, short)
9.5.2 Assembly of MK module
722
- Screw in 2 stud bolts (722, long)
500
Rotary shaft
seal pointing
upwards
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614 904
1004
- Put on 2 O-rings (614)

710
ber
718
- Put on pressure plate (718)
Screw (740) rotor part 1 together with

part 2 (904, 1004) and push it on the
shaft.
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732
- Put on 1 distance sleeve (732)
- Screw on pressing screw (730)

730
Locking
pin

the shaft (426) and tighten the
pressing screw (730) clockwise us-
ing the open-end wrench OW10
The pressing screw (730) should be screwed hand-tight and

then be tightened with a tightening torque of approx. 17 Nm. It
is recommended to additionally lock the thread with a liquid
but with normal tools detachable screw locking (e.g.
LOCTITE).
Note 86
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- Put on housing (728) with O-ring

(602)
728,
602
Premount stator with adjusting ring

- Insert O-ring (603) in stator part 2
906, (1006)
604 - Screw both star knob screws (734)
with locking nut (736) onto adjusting
ring (716). Screw on star knob
1006,
screws only until the thread takes
603 hold. Do not tighten the locking nuts.
- Insert adjusting ring (716) with its
nose into the keyway of the stator
734,
part 2 (1006)
736
- Fix stator part 1 (906) with stator
716 part 2 (1006) using the two hexagon
head screws (712). Pay attention
Place premounted stator unit that the adjusting ring can be freely
rotated in the keyway between the
630 two stators.
- Push the premounted unit into

614 housing (728) from above
- Insert O-ring (604) into stator part 1
(906) (product sealing)
728 - Put on both O-rings (614) (sealing of
heating jacket)
- Insert O-ring (630) into housing
(728) (sealing of heating jacket)
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704 - Put on inlet flange (704)

- Insert one O-ring (624) each into the
two cap nuts, if necessary grease it
- Tighten both cap nuts (720)
720
434
434
Before commissioning the device with colloid mill MK module,

the running clearance between rotor and stator must be
adjusted (see also 7.3.2.2). Otherwise the device might be
damaged.
Attention
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10 Maintenance
10.1 The rotary shaft seal
The device may only run dry for a short period, otherwise the
rotary shaft seal on the product side will be destroyed.
Attention
The rotary shaft seal made of a special PTFE compound can yield an excellent service life if:
• permissible pressure ratios prevail
• no abrasive product is used
• sufficient moistening and cooling by a continuous product flow is given
The rotary shaft seal itself is subject to a certain degree of wear. The wear is dependent on:
• the pressure difference
• the temperature
• the abrasiveness of the dispersing material
• the speed
Any damage to the seal can be detected by the following:

• Dispersing material escapes at the side through the two windows of the bearing lantern
• Pressure drop in the product chamber with closed system
When changing the dispersing material, it should be checked

if the material of the rotary shaft seal and the O-rings is still
suitable. It may be necessary to replace the parts against
parts made of other materials.
Note
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10.2 The generators

The generators (904) of the machine are located above the rotary shaft seal on the drive shaft.
The generator is fine-toothed and for this reason quite sensitive.
In case of strongly baking and hardening materials, the generators must be rinsed after operation is
completed.
In order to ensure protection of the machine against foreign bodies such as screws, stones, welding
beads etc. on the generators, it is recommended that a sieve or filter is placed in front of the machine
prior to feeding in substances.
Depending on the abrasiveness of the product to be mixed, the generators are subject to a certain
degree of wear. As the size of the shearing gap has an influence on the mixing quality, the tools
should be checked for wear from time to time.
10.3 The bearings

The bearings, which are sealed on both sides, are filled with a lithium-based grease. The bearings
are provided with a lifetime lubrication and are maintenance-free.
10.4 Drive shaft

Disassembly of the drive shaft is not necessary in case of intended use of the device. It is for exam-
ple only necessary to disassemble the drive shaft if bearing or shaft are damaged. In such a case,
the IKA service is readily at your disposal or we can deliver a completely premounted bearing lantern
as replacement. Repair work may only be carried out by an expert. Should you nevertheless want to
repair the device yourselves and have the necessary specialist knowledge, a general description of
the individual procedures is given here:
10.4.1 Disassembly of the drive shaft
• Disassembly of generator and flange gasket
• Loosen the hexagon head screw (212)
• In order to release the V-belt, unscrew the locking nut (223) and turn the adjusting screw (222)
outwards
• Remove V-belt (306) and unscrew hexagon socket set screw (304)
• Pull off V-belt pulley (302), unscrew hexagon head screw (430), and take off lantern
• Unscrew hexagon socket head cap screw (429) and pull off lantern base
• Unscrew hexagon socket set screw (416) and hexagon head screw (410),
• Force adjusting ring (415) and cover (408) off using the bearing cover (412)
• Press drive shaft (426) upwards out of the bearing seat
• Remove circlip (404, 439)
• Force bearing (418, 438) off of the shaft
10.4.2 Assembly of drive shaft

Assembly is carried out in reverse order to disassembly.
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10.5 Tensioning the V-belt

Explanations of the terms
E = Depth of impression per 100 mm of belt length mm

Ea = Depth of impression of the end of the belt mm
f = Test load per V-belt N
k = Constant to calculate the centrifugal force

L = Distance between centres of the drive mm
Sa = Minimum axle load in a static condition N
v = Belt speed m/s
P = Power to be transmitted by the belt drive kW
PB = Calculation power kW
c1 = Angular factor
c2 = Operating factor
x/y = Adjustability of the difference between centres enom mm
z = Number of belts
ß = Angle of belt contact of the small pulley °
T = Minimum belt force in a static condition per belt N
PB = P x c2
The belt tension is correct if the belt given an impression force

of 7.4 N can be impressed by a value of Ea = 4 mm.
Note
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Increasing the tension:

The device will be delivered with the correct belt tension. After approx. 4 hours at full load, the initial
tension of the V-belt must be checked and, if necessary, the tension must be increased. This way the
initial elongation of a new belt is compensated:
Procedure to increase the tension (see also spare parts drawing 13.2)
• Disconnect the current supply
• Dismount accessories, such as shut-off valves, hoppers etc.
• Detach piping from the inlet and outlet side
• Lay device down, unscrew the feet
• Unscrew bottom plate
• Loosen motor fixing screws (212), but do not unscrew them!
• Loosen locking nut (223)
• Adjust the belt tension to the specified value using adjusting screw (222)
• Tighten locking nut (223)
• Tighten motor fixing screws (212)
• Screw on bottom plate and feet
• Place the device upright and align it using the feet, check the stability of the device.
• Connect the pipework, if necessary, connect accessories
Protection against influences of high temperatures, humidity, and chemical substances:

The V-belt is insensitive to higher or low ambient temperatures. It can easily be used at temperatures
of -30 °C up to +70 °C.
The V-belt is electrically conductive (according to DIN 7867), oil-resistant, and partly resistant to
weak acids.
Maintenance and operational safety:

We recommend to check the V-belt at regular intervals. During this, check the initial tension and, if
necessary, correct it. The V-belt does not require special care.
Belt wax or similar agents have a detrimental effect and must absolutely not be used.
The surfaces of the groove faces and the belts must not be dirty.
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11 Troubles/Causes and troubleshooting
Cause Troubleshooting
inadmissible temperature
Motor does not start
too low rate of flow

Strong vibrations
Motor overload
Unusual noise
Leakage
increase
• Failure of the mains voltage Check of the voltage supply by

authorised personnel
• Voltage supply off Plug in the plug, main switch ON
• Activation of the temperature Let motor cool down, reduce
monitoring of the motor motor load
• Motor only runs with 2 phases Check electrical connection
• • high viscosity of the product or Throttle rate of flow, reduce
unfavourable rheological product speed
characteristics
• High speeds, particularly with Reduce speed
Dispax Reactor ® DR module
• • • Eccentricity of the shaft Align or replace shaft
• • Unbalance of the mixing tool(s) Clean rotating parts, if necessary,
possibly due to baking product or rebalance or replace them, re-
wear place worn parts
• • Bearing defective Replace bearing
• • Motor mounting defective Replace mounting or motor
• Device badly aligned Realign device
• Rotary shaft seal on the product Replace rotary shaft seal
side leaks
• Static O-ring seal between the Place O-rings carefully into the
housing parts leaks groove and replace them if dam-
aged
• Flanged connections leak Retighten the connection, replace
defective seals
• Outlet valve closed while machine Do not keep the valve closed for
is running a longer period
93
IKA® WORKS
inadmissible temperature in- Cause Troubleshooting

Motor does not start
too low rate of flow

Strong vibrations
Motor overload
Unusual noise
Leakage
crease
• Prolonged circulating operation Connect a cooling unit at the cir-

with high output culating hopper
• Speed too high Reduce speed
• Ambient temperature too high Improve ventilation
• V-belt sings Increase the V-belt tension
• Foreign bodies in the mixing Clean machine and check parts
chamber for damages
• Pump delivers against too high Further open the control valve,
pressure reduce resistance of the pipework
• Supply line or mixing chamber Remove deposits in the machine
clogged up and/or pipework
• trapped air in the mixing chamber Vent device and/or suction pipe
or suction pipe, particularly in
case of horizontal suction pipe
• Wrong direction of rotation Change 2 phases of the current
supply
• too low speed Increasing the speed
• • Wear of the interior parts Replace worn parts
• no belt tension Tension belt or, if worn, replace it
94
IKA® WORKS
12 Ordering spare parts
Please use the form below to order spare parts. This enables us to handle merchandise swiftly and
smoothly.
Please proceed as follows:
Please indicate your full address and the address to which the goods should be delivered (if differ-
ent).
Please enter the part you require in the table below. The exact designation can be obtained from the
piece lists. Please always indicate the item, the designation, and the order number.
Example:
Order Serial number:
Invoice address:
13 Spare parts list and drawings:
13.1 Machine spare parts list

POS Part # Description QTY
100 P005002 MOT,2HP,#56-C,230/460/3/60/3600+ 1
104 P005117 SCREW,SH CTSK,316SS,3/8INNCX.75IN+ 3
110 S11XXACAAAAXX4 UTL 2000/4+ 1
X
202 R20-097905 FRAME,BASE,SS,2000/4 1
204 R1052672 FOOT,ADJ,M12,W/RUBBER,2000/4 4
206 R24-097915 INSERT,THREADED,316SS,M8XM12 4
210 P005158 PLATE,MTG,MOTOR,SS,56C,2000/4 1
212 P005119 SCREW,SH CTSK,316SS,M10X16+ 4
95
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214 R24-097922 NUT,TEE,STL,M10,MOT ADJ,2000/4 4

216 P005510 SCREW,SH CTSK,316SS,M6X16+ 2
217 R24-097923 BLOCK,MOTOR,ADJ,316SS,2000/4 1
222 P005511 SCREW,HHC,316SS,M6X35+ 1
223 P004720 NUT,HEX,316,M6 1
230 P001413 SCREW,SHC,LOW HEAD,316SS,M5X12+ 4
232 R23-097921 PLATE,COVER,BOTTOM,2000/4 1
302 R1054790 SHV,56MM,ALUM,16MM,UNIT,2000/4 1
304 P003175 SCREW,SKT SET,CON PT,316SS,M8X8+ 2
306 R1057758 BELT,MICRO V,711 PJ-04-EL,2000/4 1
310 R1057753 SHV,125MM,ALUM,.625IN,2000/4 60HZ 1
402 P001049 KEY,PARALLEL,316SS,4X4X45 1
404 P005505 RING,RTNG,EXT,304SS,20X1.2+ 1
408 R24-097904 SEAL,CENTRIFURAL,316SS,2000/4 1
410 P005504 SCREW,HHC,316SS,M5X12+ 3
412 R24-097899 CAP,BRG,UNIT SIDE,SS,2000/4 1
415 R24-097917 COLLAR,SHAFT,316SS,2000/4 1
416 P005506 SCREW,SKT SET,CON PT,304,M4X4+ 1
417 R24-097928 SPACER,BRG DIST,316SS,2000/4 1
418 P002452 BEARING,BALL,2X RUBR 2
SHLD,20X42X12+
422 R24-097872 PLATE,SEAL COVER,316SS,2000/4 2
424 P004936 SCREW,SHC,LOW HEAD,316SS,M4X10 4
426 R23-097876 SHAFT,DRIVE,2000/4,316SS,L3 1
427 R23-097838 FLG,LTRN,BASE,316SS,2000/4 1
428 R22-097839 FLG,LTRN,316SS,2000/4 1
429 P005507 SCREW,SHC,316SS,M6X20+ 4
430 P005203 SCREW,HHC,316SS,M8X16+ 4
432 P005509 KEY,PARALLEL,316SS,5X5X22+ 1
434 P000020 FTG,PIPE,PLUG,SH,SS,R1/8IN+ 3
438 R1052690 BEARING,BALL,2XRUBR SHLD,17X35X10+ 1
439 P005508 RING,RTNG,EXT,304SS,17X1+ 1
500 P005503 HOUSING,SEAL,2000/4 1
501 R1054617 SEAL,RDL SFT,PTFE,2000/4 1
502 R1057196 RING,RTNG,INT,SS,28X1.2+ 1
600 P005123 ORING,SET,VIT,UTL2000/4 1
608 P004440 ORING,VIT,101.32X1.78+ 2
610 P004878 ORING,VIT,69.57X1.78 2
612 P004879 ORING,VIT,50.52X1.78 1
614 P005096 ORING,VIT,8X3 2
620 P004880 ORING,VIT,20.35X1.78 1
622 P004574 ORING,VIT,28.3X1.78+ 1
624 P004704 ORING,VIT,10X1+ 2
704 R1056121 FLG,INLET,1IN S-FTG,2000/4 1
710 R1056118 CHAMBER,DISP,.75 S-FTG,2000/4 1
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IKA® WORKS
720 R24-097206 NUT,HEX,CAP,316SS,M8,W/ORING GRV 2

722 R24-097866 STUD,316SS,M8X70(80),UTL2000/4 2
730 R24-097892 NUT,HEX,CAP,316SS,M8,2000/4 1
732 R24-097900 SPACER,ROTOR 1
904 R23-098032 ROTOR,MDM(4M),316SS,2000/4 1
905 R24-097916 SPACER,ROTOR,DIS,316SS,2000/4 1
906 R23-098031 STATOR,MDM(4M),316SS,2000/4 1
1100 R1056538 SET,TOOL,2000/4 1
1200 P005092 LABEL,SET,2000/4 1
1202 P001066 LABEL,DIRECTION ARROW 1
1204 P001070 LABEL,PROCESSING EQUIP,IKA WORKS 1
1208 P004885 LABEL,SERIAL NO,304SS,2000 SERIES 1
1218 P002428 LABEL,SERIAL NUMBER,SMALL 1
97
IKA® WORKS
13.2 Figure 3 Machine spare parts drawing
98
IKA® WORKS
13.2.1 Figure 4 Detail of figure 3
99
IKA® WORKS
13.2.2 Figure 5 Detail of figure 3
100
IKA® WORKS
13.3
13.4 - DR Module Spare parts list and drawing

608 2 pc. P004440 ORING,VIT,101.32X1.78
610 2 pc. P004878 ORING,VIT,69.57X1.78
722 2 pc. R24-098035 STUD,316SS,M8X110(120) DR2000/4
804 1 pc. R23-098027 ROTOR,CRS(2G),316SS,2000/4
806 1 pc. R23-098026 STATOR,CRS(2G),316SS,2000/4
1004 1 pc. R23-097869 ROTOR,FINE(6F),316SS,2000/4
1006 1 pc. R23-097853 STATOR,FINE(6F),316SS,2000/4
101
IKA® WORKS
DR module
The following table specifies the speed range to operate the DR module. It is recommended that you
operate within these specifications. Exceeding these ranges may result in mechanical failure
DR 3140-7900 24-60 1440-3600 8.5-23
102
IKA® WORKS
13.5 - MHD Module Spare parts list and drawing

608 2 pc. P004440 ORING,VIT,101.32X1.78
610 2 pc. P004878 ORING,VIT,69.57X1.78
625 1 pc. P005160 ORING,VIT,53.57X3.53
704 1 pc. R1056121 FLG,INLET,1IN S-FTG,2000/42000/4
708 1 pc. R1057350 FLG,INLET,.75""S-FTG,LIQ,MHD2000/4
722 2 pc. R24-098035 PADDLE,A,316SS,45DEG,MHD2000/4
802 1 pc. R24-098037 Feeding screw Ø47-1SA DN 50
804 2 pc. R23-098027 ROTOR,CRS(2G),316SS,2000/4
806 1 pc. R24-098038 PADDLE,B,316SS,45DEG,MHD2000/4
902 1 pc. R24-098040 MANTLE,(CRS)5MM DIA,MHD2000/4
1004 1 pc. R23-098034 ROTOR,CRS(1P),316SS,MHD2000/4
1006 1 Pc. R23-098026 STATOR,CRS(2G),316SS,2000/4
103
IKA® WORKS
MHD mod-
ule
1006
1004
The following table specifies the speed range to operate the MHD module. It is recommended that
you operate within these specifications. Exceeding these ranges may result in mechanical failure.

MHD 3140-7900 24-60 1440-3600 8.5-23
104
IKA® WORKS
13.6 - MK Module Spare parts list and drawing

603 1 pc. 1050493 O-ring FPM 58.42x2.62
604 1 pc. 1055255 O-ring FPM 42.52x2.62
614 2 pc. 1053789 O-ring FPM 8x3
626 1 pc. 1055256 O-ring FPM 66.34x2.62
627 1 pc. S104861 Seal G
630 2 pc. 1050460 O-ring FPM 9.25x1.78
704 1 pc. 1054919 Inlet flange DN25 DIN11851
712 2 pc. S100692 Hexagon head screw DIN 933 M6x10-A2
716 1 pc. 1055068 Adjusting ring
718 1 pc. 1054918 Pressure plate
722 2 pc. S098035 Stud bolt M8x110
728 1 pc. 1055015 Housing
734 2 pc. S104317 Star knob screw GN6336.5-ST-32-M6-20
736 2 pc. 1045338 Hexagon nut DIN 439 M6-A2
740 2 pc. 1034421 Hexagon socket head cap screw DIN 912 M5x12-A2
904 1 pc. 1055160 Rotor part 1, z=32
906 1 pc. 1055182 Stator part 1, z=34
1004 1 pc. 1055179 Rotor part 2, z=75
1006 1 pc. 1055192 Stator part 2, z=80
105
IKA® WORKS
MK module
The following table specifies the speed range to operate the MK module. It is recommended that you
operate within these specifications. Exceeding these ranges may result in mechanical failure.

MK 3140-7900 24-60 1440-3600 8.5-23
14 Appendix
14.1 Scale-Up
The LABOR-PILOT is designed in the same way as the larger production machines of the 2000 se-
ries. All important parameters can be transferred to the larger machines and thus enable an optimum
scale-up to pilot or production plants. The following table gives a survey of the individual machines:
106
IKA® WORKS
Machine type Throughput Power Machine type Throughput Power

liters/h kW liters/h kW
Single-stage dispersing machines ULTRA Mixing of powder with liquids MHD ma-
TURRAX® INLINE UTL chines
LABOR-PILOT 2004 350 1,5 LABOR-PILOT 2004 100 1,5

UTL 2000/05 2500 4 incl. MHD module
UTL 2000/10 8000 7,5 MHD 2000/05 750 4
UTL 2000/20 20000 22 MHD 2000/10 2500 7,5
UTL 2000/30 40000 37 MHD 2000/20 7500 15
UTL 2000/40 70000 55 MHD 2000/30 20000 30
UTL 2000/50 125000 110 MHD 2000/50 40000 75
Three-stage dispersing machines DISPAX Colloid mill MK

REACTOR® DR
LABOR-PILOT 2004 300 1,5
LABOR-PILOT 2004 350 1,5 incl. MK module
incl. DR module (7900 MK 2000/05 2500 4
rpm) MK 2000/10 7500 11
DR 2000/50 2500 5,5 MK 2000/20 20000 22
DR 2000/10 8000 15 MK 2000/30 40000 45
DR 2000/20 20000 37 MK 2000/50 80000 90
DR 2000/30 40000 55
DR 2000/40 70000 90
DR 2000/50 125000 160
Three-stage dispersing machines with par-

ticularly high circumferential speeds Super
DISPAX REACTOR® DRS
LABOR-PILOT 2004 550 1,5

incl. DR module
(13700 rpm)
DRS 2000/05 1200 7,5
DRS 2000/10 2500 15
DRS 2000/20 7500 37
DRS 2000/30 20000 75
DRS 2000/50 40000 200
107
IKA® WORKS
Europa – Afrika America Asien - Australien
IKA WERKE IKA WORKS, INC. IKA WORKS, (Asia) Sdn Bhd
----------------------------------------------------- ------------------------------------------------- ----------------------------------------------------------
LABORTECHNIK LABOR- TECHNOLOGY LABOR- TECHNOLOGY

ANALYSENTECHNIK ANALYZING TECHNOLOGY ANALYZING TECHNOLOGY
MASCHINENBAU PROCESSING EQUIPMENT PROCESSING EQUIPMENT
IKA WERKE GmbH & Co. KG IKA WORKS, INC. IKA WORKS (Asia) Sdn Bhd
Janke & Kunkel-Str. 10 2635 NORTH CHASE PKWY, SE (Company No. 340448-K)
D 79219 Staufen WILMINGTON, NC 28405-7419 No. 3, Lot PT 3403,
GERMANY TEL.: 800/733-3037 Batu 22 ¾ Lebuh Raya,
TEL.: 07633/831-0 TEL.: 910/452-7059 Kuala Lumpur- Serendah,
FAX: 07633/831-98 FAX: 910/452-7693 48200 Serendah
E-mail: sales@ika.de E-mail: process@ika.net Selangor, Malaysia
Internet: http://www.ika.net TEL.: (603) 601 3122
http://www.ikaprocess.com FAX: (603) 601 3126
E-mail: ika@tm.net.my
______________________________________________________________________________
http://www.ikaprocess.com
______________________________________________________________________________
108

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IKA WORKS

1 EC DECLARATION OF CONFORMITY .............................................................................................................5

2 FOR YOUR SAFETY..............................................................................................................................................7

5.2.4 Connection on the suction side ................................................................................................................... 34

9.4.2 Assembly of MHD module ...........................................................................................................................79

12 ORDERING SPARE PARTS ................................................................................................................................95

13 SPARE PARTS LIST AND DRAWINGS:............................................................................................................95

Herewith we, IKA® - WERKE GMBH & Co. KG

Designation of the machine: LABOR-PILOT

Relevant EC directives: 98/37/EEC, Appendix II A

Applied national standards

2 For your safety

2.1 General dangers

2.3 Correct use

2.4 Safety precautions

2.4.1 User's duty of care

2.4.2 Special safety information and symbols used

This symbol does not point to safety information, but to in-

2.4.3 General safety information

Modifications of the system and parts of it are only allowed with

2.4.4 Basic safety precautions during normal operation

Replace all hose lines at regular intervals as a preventive mainte-

When changing the dispersing material, it should be checked if the

The machine is not suitable for processing abrasive substances.

2.4.5 Basic safety precautions during service and maintenance

The machine may only be maintained by qualified and

2.4.6 Work on the electrical equipment

Connection of the device must correspond to VDE standards.

2.4.7 Observe the environmental protection regulations

2.5 Other dangers

3 Description of the LABOR-PILOT 2000/4

3.1 Before using the LABOR-PILOT

3.2 Description of the device

3.2.1 Description of the main unit and of the attached notes

Lantern with flange gasket

3.2.2 Electronic control

3.3 Principle of operation

3.3.1 Modular design

3.3.2 Principle of operation of the basic device

Generator – pumping stage Generator, coarse-

Generator, medium- Generator, fine-

3.3.3 Principle of operation of the Module DISPAX-REACTOR® DR

3.3.4 Principle of operation of the MHD module

Proportioning device Remark

3.4.1 Figure 1 Dimension sheet

3.4.2 Figure 2 Dimension sheet

LABOR-PILOT 2000/4 for operation with LABOR-PILOT CONTROLLER

3.4.3 Figure 3 Dimension sheet

Basic device DR module MHD module MK module

3.4.4 Dimension table

Basic device LABOR-PILOT 2000/4 DN 25 DN 15 - 305

Operation as basic device without speed regulation

Operation with speed regulation at the LABOR-PILOT CONTROLLER

Other general data

Max. throughput rates

Basic device, single-stage, generators 2G, 4M, 6F : approx. 350 liters/h

4.2 Electrical system

Mains power supply

Motor current measurement: