RK-EF-25 Double-walled reaction vessel with Easy
Contents
1. bottom outlet J valve to clean the vessel When you reinstall the valve you should make sure it is opened Otherwise you could damage the valve seat or the valve spindle KGW ISOTHERM page 9 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame 7 Putting Into Operation Before the vessel is put into operation the owner needs to look for cracks scratches and other signs of damage on the surface of the glass and in the glass itself You should also examine the glass surface for signs of chemical wear if applicable Vessels with signs of surface damage wear and tear et cetera should not be used They could implode when placed under thermal or mechanical stress When putting the vessel into operation you should avoid any start up processes that could lead to surges in pressure The tempering medium circuit must be depressurized and fully evacuated of air before being put into operation When starting up or shutting down the vessel you must make sure to increase decrease the circulation flow slowly Quickly increasing or decreasing the circulation flow can produce sudden surges in pressure that could destroy the vessel Due to the double walled vessel s special design you must make sure when filling the empty vessel that the difference between the medium temperature and the thermal jacket temperature is not heigher than 30 K When you are adding a medium to a vessel y2. devices A Setting board Tubular safety pieces J Vi E AZ Z KGW ISOTHERM page 5 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame 2 Safety Information 2 1 General Safety Information for Vessel Owners This operating manual contains basic information on setting up operating and servicing your vessel The vessel owner and designated personnel should a read this manual before performing any such activities b follow its instructions while performing the activities and c make sure the manual is available wherever the double walled vessel is being used They should also follow the following rules All applicable national regulations on accident prevention electrical equipment static electricity transportation equipment environmental protection and explosion prevention The vessel owner s in house process specifications operating instructions and safety regulations If you have any questions please contact KGW ISOTHERM in Karlsruhe Germany 2 2 General Safety Information for Vessel Operators o Do not perform any activity that could make the double walled vessel and or the system less safe o As a general rule you should only work on the double walled vessel once it has gone out of operation and reached ambient temperature Before disassembling the vessel make sure it does not contain any substances that are hazardous to the environ
3. 3 The sealant No 3 can now be placed into the metal adapter cage No 4 4 The metal adapter cage No 4 will be pushed against the glass flange No 1 and fastened by means of the cap nut No 2 5 Afterwards the metal hose of the thermostat can be connected to the metal adapter No 4 Spare parts A Metal adapter complete for DN 15 part no 4200 B Sealant out of silicon part no 4201 C Sealant out of PTFE GORE part no 4202 D Metal hoses thermal insulated up to 300 C Screw connection M16 x 1 Length 1 0 metre part no 4216 Length 1 5 metre part no 4217 Length 2 0 metre part no 4218 E Metal adapter complete for DN 15 with olive 13mm part no 4153 KGW ISOTHERM page 12 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 97 9 2012 vessel with Easy Frame Mounting instruction for Bottom outlet valve Type J A Set the valve plunger 1 into the guide sleeve 2 and secure it with split pin 3 Then please screw the V2A thread into valve body 4 against the clockwise direction as far as it will go The square of the guide sleeve must be inserted into the appropriate drilling of the valve body Screw Lock nut 5 one revolution onto valve body Insert Seal 8 into glass flange 6a and press it up to the restriction Push the valve as far as it will go into the glass part and push in the steel spring 7 up to extension in the tangential drilling of lo
4. Mounting instruction amp users manual KGW ISOTHERM RK EF 25 Double walled reaction 27992912 vessel with Easy Frame Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame Table of Contents No Page 1 Mounting Instruction for complete Reactors with EASY FRAME 3 2 Safety Information 6 2 1 General Safety Information for Vessel Owners 2 2 General Safety Information for Vessel Operators 2 3 Types of Safety Warnings 2 4 Personnel Qualifications 2 5 Hazards of Ignoring the Safety Warnings 2 6 Alterations and Spare Parts 2 Correct and Incorrect Ways to Operate the Vessel 2 8 Safety Warnings for Operations in Hazardous Areas 3 Liability for Defects as to Quality 8 4 Transportation 8 5 General Information 8 5 a Manufacturer s Declaration 5 0 Design 5 C Specifications Limits of Use 6 Mounting the Double walled Vessel 9 7 Putting Into Operation 10 8 Maintenance Servicing Repairs 10 9 Diagram of a Double walled Reactor 11 10 Practice Advise for Metal Adapter DN 15 12 11 Practice Advice for Industrial Valve type J 13 12 Mounting the Lid on a Double walled Vessel 14 13 Technical Data of Reaction Vessel 15 14 Stirrer seal out of glass RV 16 45 16 15 Part List and Spare Parts for Easy Frame Assembly 18 KGW ISOTHERM page 2 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Fram
5. cal or chemical influences o Problems with important functions o Environmental pollution from hazardous material leaks 2 6 Alterations and Spare Parts The vessel owner may only alter or modify the double walled vessel in consultation and agreement with the manufacturer For your safety you should only use original spare parts and accessories authorized by the manufacturer Using other parts may render the manufacturer s liability for any consequences null and void 2 7 Correct and Incorrect Ways to Operate the Vessel The vessel must be operated as indicated in this manual under point 5 to ensure adequate safety If you operate the vessel in any other way or with media which may attack the vessel materials we may disclaim any and all liability for the consequences Also The vessel may only be operated if it is in flawless condition 2 8 Safety Warnings for Operations in Hazardous Areas If you operate glass apparatuses in hazardous areas in a way that may lead to explosive discharges of static electricity you must take appropriate precautions The extent of these precautions depends on the probability that an explosive atmosphere will be created This probability in terms of time and location is broken down into zones that depend on the areas in which the device is to operate The zones correspond to the Equipment Categories laid out in Directive 94 9 EC For more details on how electrostatic ignition hazards are caused evaluated and avoi
6. ck nut 5 Afterwards tighten lock nut until the guide sleeve is resting upon on the seal By further tightening of the lock nut now the pressure on the seal can be adjusted Note do not tighten the lock nut with excessive force since thereby the abrasion of seal increases E By turning of the valve cap 9 in the clockwise direction the valve is closing The maximum stroke length of the drain valve amounts to 50 mm which can be used fully In order to ensure the function of the built in safety spring of valve the valve cap must kept turning approx 2 revolutions after the valve is closed this correspond to 5 mm possible safety feed motion KGW ISOTHERM page 13 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame General Advices for Industrial valve Type J As long as the split pin is not visible in the valve body turning the valve cap in any case can retighten the safety spring Should the split pin become visible and a distance of approx 5 mm up to the end of the guide groove is under run the exchange of the valve temple is recommended since the stamp point itself has worn out and so in the same measure it reduces the safety spring motion The vessel was equipped with a Bottom Outlet valve Type J Industrial Version The bottom outlet valve Type J has got a spring pressured PTFE plunger for constant seal pressure at various temperatures Temperatur
7. ded please consult Guideline BGR 132 on static electricity issued by BG Chemie KGW ISOTHERM page 7 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame 3 Liability for Defects as to Quality Our liability for defects as to quality is as laid out in our General Terms and Conditions of Sale and Delivery as they may change from time to time Please notify us immediately if damages occur during the contractually agreed upon period This is the only way you can safeguard your rights to a remedy in case of defects as to quality We are only liable if the permitted operating conditions were complied with and the material s resistance to the media was considered As set forth in our valid Terms and Conditions of Sale and Delivery we disclaim all liability for damages sustained by the failure to observe these requirements 4 Transportation Any transportation must comply with generally accepted technical conventions accident prevention regulations regulations on handling and using transportation and lifting equipment including the manufacturer s instructions and in house safety rules Every double walled vessel is delivered packaged in boxes cases The vessel must be protected Achtung E against shock impact or any other mechanical stress when you unpack the parts and transport them on your own premises Achtung 8 Keep people outside of the hazard area i 0 E 5 Genera
8. e 1 Mounting Instruction for complete Reactors with EASY FRAME 1 Setthe frame straighten it and secure the wheels with the help of the breaks 2 Release the aluminium setting board with the help of the headless pins Adjust the complete stage to the desired height and fasten the headless pins again Afterwards please secure the board with the tubular safety piecess from the bottom 3 The bars of the flange holders might be removed for transport The bars must be put into the fasteners from inside again 4 The aluminium setting board must have cork cushioning 5 Put the reactor on top of this cushioning insert and turn it into the desired position e g thermal jacket connections in the background 6 Afterwards the complete stage of flange holders must now be adjusted so that the flange holders can be fixed in the height of the reactor neck Therefore please loosen the headless pins inside of the blue coated connectors move the complete stage and fasten the headless pins again Flange holder 7 Now set the stirrer seal KGW 40466 on the centre socket NS 45 40 of the lid and secure it with a suitable clamp for NS 45 40 8 Lead the stirrer element Anchor or Propeller Stirrer from downwards through the stirrer seal and secure it with the help of the pressure screw please see below under Practice Advice for Stirrer Sealant KGW ISOTHERM page 3 of 19 12 13 14 15 16 Mounting instructio
9. e range from 120 to 200 C On request such vessels can be equipped with other thermal jacket connections or other bottom outlets 12 Mounting the Lid on a Doble walled Vessel Make sure to wear protective goggles or a facemask as well as protective gloves whenever you handle or work with the reaction vessels Only properly trained personnel should install glass components in KGW supporting frames or in mounting equipment provided by the customer The glass components must be installed without stress All external connections on the double walled vessel must be connected without stress On an Easy Frame the Lid will be fixed to the Reactor with the help of a Quick release Clamp Lid J 5 Quick release clamp Jdal O ring o Reactor KGW ISOTHERM page 14 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame 13 Technical Data of Reaction Vessel Reactions Vessel Type TRGN 7198 20 Capacity 20 Litres Flange NW 200 DIN 12214 Maximum Overpressure of Reactor 0 5 bar Temperature range maximum 200 C Temperature range minimum 70C Bottom Outlet Valve J Valve 10mm Capacity of Thermal Jacket of Reactor approx 6 5 Litres Material Borosilicate glass 3 3 DIN ISO 3585 H i 725 F H 650 KGW ISOTHERM page 15 of 19 Mounting instruction amp
10. ential max 30 max 30 in the glass wall The bottom outlet J valve is spring loaded to maintain the same level of closing force at different temperatures The vessel is equipped with DN15 glass flanges as thermal jacket connection They have different temperature ranges depending on used sealants standard PTFE sealants Thermal jacket connection DN15 with PTFE sealants Temperature range from 120 to 200 6 Mounting the Double walled Vessel Make sure to wear protective goggles or a facemask as well as protective gloves whenever you handle or work with reaction vessels Only properly trained personnel should install glass components in KGW supporting frames or in mounting equipment provided by the customer The glass components must be installed without stress All external connections on the double walled vessel must be connected without stress Glass vessels with several fused walls are held in place using standard stainless steel connectors with a supporting ring or on aluminium plates Easy Frame in a supporting frame that holds the vessel s entire weight To ensure adequate safety the vessel must also be installed in an enclosure protective wall made of transparent plastic to protect the operator if the vessel is destroyed The product space and the thermal jacket must be equipped with a pressure relief device to prevent the maximum permissible operating pressure from being exceeded You may have to remove the
11. hine IKA Part No 11230CV Pieces 1 13 Tempering metal hose 1 5 metre Part No 4217 Pieces 2 KGW ISOTHERM page 18 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame 9 g E i I 6 i 7 a Pei I a a tet HI La 5 E o Im 13 gt 2 1 10 13 o oo KGW ISOTHERM page 19 of 19
12. l Information 5 a Manufacturer s Declaration The triple walled vessel was manufactured by KGW ISOTHERM Karlsruher Glastechnisches Werk Schieder GmbH Gablonzer Str 6 D 76185 Karlsruhe Phone 49 0 721 958 97 0 Fax 49 0 721 958 97 77 Email info kgw isotherm de Please contact the manufacturer if you have any questions about assembling connecting operating servicing repairing or eliminating faults on the vessel KGW ISOTHERM page 8 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame 5 6 Design Double walled vessels contain two walls that have been fused together The space between the inner and the outer wall will be filled with the tempering medium You will generally have to install a pressure relief device rated at 0 5 bar before you can fill the vessel with a liquid tempering medium As a general rule the vessel is outfitted with a bottom outlet J valve designed to automatically adjust to changes in the extension of the PTFE valve spindle 5 c Specifications Limits of Use The standard rules for calculating pressure resistance do not apply to vessels with two fused walls Their design and construction are too complicated That is why these vessels are individually pressure tested The vessels can be used in the following operating conditions Productspace Thermal jacket 1 0 5 bar 70 200 70 200 Temperature differ
13. ment and or human health Once you are finished with your work you must immediately re attach all the protective and safety devices o Before performing any maintenance or repairs you must ensure that the apparatus cannot be turned on again 2 3 Types of Safety Warnings This operating manual contains safety warnings that if not followed could pose a serious health hazard These warnings are labelled as follows General hazard symbol Electrical voltage warning Safety warnings that if not followed could pose a risk to the vessel and its functionality KGW ISOTHERM page 6 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame 2 4 Personnel Qualifications The employees who assemble connect test run operate service and eliminate faults on the vessel must be appropriately qualified or adequately trained The vessel owner must Make clear arrangements regarding personnel responsibilities and supervision Ensure the personnel fully understand the contents of the operating manual s 2 5 Hazards of Ignoring the Safety Warnings If you ignore the safety warnings you could put yourself other personnel the environment and the vessel as well as the apparatus system at risk and free KGW ISOTHERM of any and all liability for defects as to quality The hazards of ignoring safety warnings may include for example o Injuries due to electrical mechani
14. n amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame Put the o ring NW 200 KGW 4061 into the groove of the reactor flange Now put this lid unit consisting of lid stirrer seal and stirrer element on top of the reactor flange The reactor and the lid will now be closed with the help of the quick release clamp KGW 4051 Please put the stirrer coupling on the shaft relief of stirrer element and fasten it Now put both PTFE seals KGW 4202 for the thermostat hoses into the metal adapters KGW 4200 and screw them on the DN15 flanges please see practice advices for metal adapters The transport securing of the thermal jacket flanges must possibly the removed at first Connect the thermostat hoses with the metal adapters and your thermostat Fasten the stirring machine with a cross clamp on its bracket to the middle tube of frame This centred tube must possibly be height adjusted a little Connect the stirrer element with the help of this stirrer coupling with the chuck of Stirring machine please pay attention that the stirrer is strictly aligned Now the reactor is ready to use and can be put into operation KGW ISOTHERM page 4 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame q gt Ie DI S Holder for stirring machine Flange holder E T with bars 72 A Stage of flange holders Immobilisin andle
15. ou have previously filled and the difference between the medium temperature and the product temperature is higher than 30 K you must make sure not to feed the medium directly onto the wall which would expose the glass to critical thermal stress 8 Maintenance Servicing Repairs If the product tends to leave deposits make sure that there are no solid particles near the valve spindle and or valve seat when you close the valve Deposits will produce leaks and could damage the valve Damaged vessels should not be put into operation Please contact the manufacturer if your vessel requires repairs KGW ISOTHERM page 10 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 982012 vessel with Easy Frame 9 Diagram of a Double walled Reactor Schott flange with nut NW 200 H i 725 F H 650 Outlet Valve Front view Operator KGW ISOTHERM page 11 of 19 Mounting instruction amp user s manual RK EF 25 Double walled reaction 7 7 vessel with Easy Frame 10 Practice Advice for Metal Adapters Construction 1 Glass flange DN 15 2 Cap nut with spring ring 3 Sealant 4 Metal adapter with thread M16 x 1 for metal hoses Installation 1 The spring ring is pulled out of the cap nut No 2 2 Now the cap nut will be pushed over the glass flange No 1 Afterwards the spring ring can be replaced into the drilling of the cap nut
16. p Cc Cc Cc DI O gt 07 05 2012 RK EF 25 Double walled reaction vessel with Easy Frame DA s gt TDD L 6 3 O D o O E 03 OC D D A D V D QA T gt a A x mm e m e AIN SSS Saa Es CE A AN Tm lt lt S Gasket kit Shaft ea 3 Bose SA e IATA ZZZ SEZ LESS KKK LL R RLS page 17 of 19 KGW ISOTHERM Mounting instruction amp user s manual RK EF 25 Double walled reaction 9782012 vessel with Easy Frame 15 Part List and Spare Parts for Easy Frame Assembly 1 Frame Type Easy Frame Part No 7706 Pieces 1 2 Reaction Vessel Part No TRGN 7198 20 Pieces 1 3 Metal Adapter DN15 to M16x1 Part No 4200 Pieces 2 4 PTFE Sealants DN 15 Part No 4202 Pieces 2 5 Silicon FEP O Ring NW 200 Part No 4061 Pieces 1 6 Lid Part No D 4302S Pieces 1 Centre socket NS 45 40 and 3x side socket NS 29 32 angular 7 Quick Release Clamp NW 200 Part No 4051 Pieces 1 8 Stirrer seal out of glass RV 16 45 Part No 40463 Pieces 1 9 Stirrer coupling RKG 16 Part No 404741 Pieces 1 10 Propeller stirrer made of stainless steel shaft Pieces 1 PD W16 V TRGN 7198 20 length 1000mm Options 11 Cross clamp Part No 112233 Pieces 1 12 Stirrer mas
17. user s manual RK EF 25 Double walled reaction 7 7 vessel with Easy Frame 14 Stirrer seal out of glass RV 16 45 XxX X Shaft and seals should be cleaned beforehand if necessary gt x lt Tighten pressure screw only after installing the stirrer shaft stirrer seal complete Slightly worn out sealing elements can be adjusted by tightening the pressure screw step less The inserted Viton compound square ring serves as form and or compensating element x Sealing elements should be exchanged in time x By appropriate installation of the sealing elements the stirrer seal is suitable both for pressure and for vacuum usage Working with pressure a sufficient fastening must be provided for the stirrer seal Examples Vacuum Pressure all purpose application Z Z 1 4 lt A AX AS AX S S Wy Wy AZ j a Stirrer seal complete Shaft diameter Size of joint Fitting length Part no mm NS mm 16 45 40 105 40466 Spare parts Pressure guide sleeve out of PTFE compound red for 16 mm shaft diameter Part no 40463 220 Gasket kit consisting of 2 lip seals and1 O ring out of PTFE for 16 mm shaft diameter Part no 40463 270 for a complete exchange you will need 2 gasket kits Pressure screw out of PTFE compound red for 16 mm shaft diameter Part no 40463 310 KGW ISOTHERM page 16 of 19 C nD Ci CO dp Al D dp DI o C O sked O DI fd d
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