Kinematica Megatron MT 5100 S2 Operating instructions

MEGATRON® MT 5100 S²
General Operating Instructions
General Installation Instructions
General Maintenance Instructions

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
2
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38
SAFETY INDICATIONS
Please pay attention to the meaning of the following warning signs:
SAFETY INSTRUCTIONS MUST BE OBSERVED TO ENSURE SAFE
OPERATION
THIS SYMBOL INDICATES HIGH VOLTAGE, WITH RISK TO
HEALTH AND ENVIRONMENT
CAUTION!
BEWARE OF HOT SURFACE
CAUTION!
BEWARE OF HAZARDOUS CHEMICALS OR MATERIALS THAT
ENDANGER HEALTH
CAUTION!
BEWARE OF ROTATING MECHANICAL PARTS
CAUTION!
DEVICE NOT DESIGNED FOR USE IN EXPLOSION DANGER
ENVIRONMENTS

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
3
of
38
GENERAL SAFETY INSTRUCTIONS
RESPECT THE INSTRUCTIONS GIVEN IN THIS DOCUMENT
READ THESE OPERATING INSTRUCTIONS BEFORE SWITCHING
ON OR OPERATING THE EQUIPMENT
IF YOU HAVE ANY QUESTIONS OR DOUBTS REGARDING
OPERATING THE UNIT, DO NOT START OR OPERATE THE UNIT
AND CONTACT YOUR DEALER OR NEAREST KINEMATICA
SERVICE CENTER
IMPROPER USE OF THE MACHINE / UNIT DUE TO
UNAUTHORIZED PERSONNEL CAN LEAD TO DAMAGE ON THE
MACHINE / UNIT AND / OR ENDANGER LIFE, CAUSE PERSONAL
INJURY AND HARM THE ENVIRONMENT
ALL AUTHORIZED PERSONNEL INVOLVED IN THE OPERATION,
THE SERVICE OR THE REPAIR OF THE MACHINE / UNIT HAVE TO
READ AND TO UNDERSTAND THIS MANUAL
ONLY AUTHORIZED PERSONNEL / INTENDED USERS ARE
ALLOWED TO USE THE MACHINE
THE INTENDED USER ASSURES THAT THE MACHINE / UNIT
WILL BE INSTALLED CORRECTLY IN ORDER TO FULFILL THE
INTENDED APPLICATION AND AUTHORIZES OTHER QUALIFIED
USERS TO WORK WITH THE MACHINE / UNIT. HE IS ALSO
RESPONSIBLE TO INSTRUCT THE USERS OF THE MACHINE /
UNIT

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
4
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38
THE SERVICE ENGINEER IS EMPLOYED BY THE INTENDED USER
AND MAINTAINS THE MACHINE / UNIT DURING OPERATION.
HE IS A SKILLED CRAFTSMAN WITH MECHANICAL, ELECTRICAL
AND ELECTRONIC EDUCATION. THE SERVICE ENGINEER IS
RESPONSIBLE FOR THE INSTALLATION AND START-UP OF THE
MACHINE / UNIT AS WELL AS FOR THE MAINTENANCE AND
REPAIR OF THE MACHINE / UNIT. HE MUST BE TRAINED
ACCORDINGLY TO CARRY OUT ALL NECESSARY
MAINTENANCE WORK
ENSURE THAT ALL LEGAL AND ENVIRONMENTAL
REGULATIONS OF THE COUNTRY WHERE THE MACHINE / UNIT
WILL BE INSTALLED ARE FOLLOWED
DO NOT MODIFY THE MACHINE / UNIT WITHOUT A WRITTEN
CONFIRMATION BY KINEMATICA
IT IS STRICTLY FORBIDDEN TO RUN THE MACHINE / UNIT WITH
DISASSEMBLED OR BRIDGED SAFEGUARDS, FOR EXAMPLE
SAFETY LIMIT SWITCH, EMERGENCY SWITCH OR COVER
FOR REPAIRS, ONLY ORIGINAL SPARE PARTS SHOULD BE USED
BEFORE STARTING INSPECTION AND MAINTENANCE WORK
ON THE MACHINE / UNIT (SERVICE, REPAIR ETC.), ALL POWER
SUPPLIES MUST BE DISCONNECTED
THE DRIVE UNIT MAY ONLY BE OPENED BY AUTHORIZED
KINEMATICA SERVICE STATIONS
SERVICE AND MAINTENANCE SHALL ONLY BE PERFORMED BY
AUTHORIZED AND SKILLED SERVICE ENGINEERS

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
5
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38
AFTER EVERY INSPECTION AND MAINTENANCE WORK ON THE
MACHINE / UNIT (SERVICE, REPAIR ETC.), THE SERVICE
ENGINEER HAS TO DO A TEST-RUN
EAR PROTECTION SHOULD ALWAYS BE USED WHEN WORKING
IN THE ENVIRONMENT OF THE MACHINE
KEEP THIS OPERATING MANUAL NEARBY THE EQUIPMENT FOR
FUTURE REFERENCE
THIS DOCUMENT IS PART OF THE MACHINE / UNIT AND
SHOULD NOT BE REMOVED OR STORED ELSEWHERE
EASY ACCESS TO THE OPERATING AND MAINTENANCE CREW
MUST BE GRANTED AT ALL TIMES
ALTHOUGH MEGATRONUNITS ARE DESIGNED FOR EASY USE,
THIS DOES NOT RELEASE YOU FROM THE OBLIGATION TO
INSPECT YOUR EQUIPMENT CAREFULLY AND TO CLEAN IT
THOROUGHLY

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
6
of
38
WARNINGS
ALL WARNINGS AND RECOMMENDATIONS IN THE FOLLOWING
CHAPTERS MUST BE RESPECTED
THE EQUIPMENT MAY NOT BE OPERATED IN EXPLOSIVE AREAS
IT IS NOT ALLOWED TO WORK WITH FLUIDS WHICH ARE
HIGHLY INFLAMMABLE
IT IS NOT ALLOWED TO MIX MATERIALS WHICH CAN CAUSE
STRONG EXOTHERMAL REACTIONS
THE ELECTRICAL INSTALLATION MUST BE DONE BY A
QUALIFIED ELECTRICIAN!
ENSURE THAT THE RATED VOLTAGE OF THE EQUIPMENT
MATCHES THE SUPPLY
IT IS IMPORTANT THAT THE MAINS SUPPLY WHERE THE DEVICE
IS PLUGGED IN COMPLIES WITH THE INFORMATION ON THE
TYPE LABEL AND THE INTERNATIONAL STANDARDS FOR
POWER SUPPLIES. IF NOT, SUCCESSFUL OPERATION CANNOT
BE GUARANTEED
ENSURE THAT ENOUGH FREE SPACE IS AVAILABLE AT THE
BACKSIDE OF DEVICE, SO THAT EFFECTIVE AIR FLOW AND
COOLING IS ASSURED – INSUFFICIENT COOLING MAY LEAD TO A
DECREASE OF POWER OUTPUT
THE DEVICE HAS TO BE PLACED IN A MANNER THAT DIRT OR
FLUIDS CANNOT PENETRATE THROUGH THE VENTILATION
SLOTS AT BACK SIDE OF THE DRIVE

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
7
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DIRECTION OF ROTATION IS COUNTER-CLOCKWISE SEEN FROM
FRONT ONTO THE COUPLING!
DRY-RUN OF MECHANICAL SEALS AND/OR SLIDE BEARINGS
MUST BE AVOIDED!
THE MECHANICAL SEAL MUST BE OPERATED WITH A SUITABLE
SEALANT LIQUID
THE QUENCH SYSTEM FOR THE MECHANICAL SEAL MUST BE
MONITORED BY THE INTENDED USER
THE INTENDED USER MUST ENSURE FLOW OF PRODUCT
THROUGH THE UNIT AT ALL TIMES
MEGATRONDISPERSION WORKING CHAMBERS MAY NOT BE
OPERATED DRY – THE MECHANICAL SEAL IS COOLED AND
LUBRICATED BY THE MEDIUM BEING PROCESSED AND THE
QUENCH MEDIUM. RUNNING DRY WILL DESTROY THE
MECHANICAL SEAL

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
8
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THE MAX. OPERATIONAL SPEED IS INDICATED ON THE DATA
PLATE
THE INTENDED USER HAS TO ENSURE THAT NO FOREIGN
PARTICLES WHICH MIGHT LEAD TO A DAMAGE CAN PASS
THROUGH THE UNIT
THE ASSEMBLY AND DISASSEMBLY PROCEDURE IS DESCRIBED IN
THIS MANUAL
THE UNIT IS ONLY ALLOWED TO BE OPERATED WHEN
ASSEMBLED COMPLETELY
NEVER PULL THE COUPLING DURING OPERATION – THE
WORKING CHAMBER COULD FALL OUT OF THE COUPLING
THE WORKING CHAMBERS SHOULD BE CLEANED AFTER EVERY
OPERATION
THE INTENDED USER HAS TO ENSURE THAT USED SOLVENTS
AND CLEANING MATERIALS ARE COMPATIBLE WITH THE
MATERIAL OF THE SEALS AND COMPONENTS OF THE UNIT
THE RESPONSIBILITY OF KEEPING THE OPERATING
PARAMATERS SUCH AS PRESSURE, TEMPERATURE AND
PRODUCT FLOW WITHIN THE SPECIFIED LIMITS LIES WITH THE
INTENDED USER
SHAFT SEALS ARE NOT ALLOWED TO BE SUBJECT TO PRESSURE

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
9
of
38
IN THE EVENT THAT HAZARDOUS CHEMICALS OR MATERIALS
THAT ENDANGER HEALTH CAN INFLUENCE THE
SURROUNDINGS OR USE OF THE EQUIPMENT, APPROPRIATE
COUNTERMEASURES MUST BE TAKEN
WHEN HANDLING DANGEROUS PRODUCTS, TAKE CARE THAT
THE LOCAL SAFETY REGULATIONS ARE RESPECTED
AT LONG TERM USE, THE WORKING CHAMBER AND THE
BEARING HOUSING / COUPLING MAY GET HOT – DANGER OF
SKIN BURN
WHEN THE LINE CORD IS PLUGGED, NEVER TOUCH THE
COUPLING IN THE DRIVE – DANGER OF INJURIES DUE TO
ROTATING EDGES
IF THE MACHINE / UNIT IS USED FOR ANY OTHER PURPOSE
THAN THE INTENDED APPLICATION OR IF THE MACHINE / UNIT
WILL BE OPERATED BEYOND THE TECHNICAL DATA RANGE
WITHOUT THE WRITTEN APPROVAL BY KINEMATICA,
IMPROPER USE IS DECLARED AND KINEMATICA WILL TAKE NO
RESPONSIBILITY, NOR WILL GRANT ANY GUARANTEE
IMPROPER USE OF THE MACHINE / UNIT CAN RESULT IN
PERSONAL INJURY OR IN DAMAGE OF THE EQUIPMENT
KINEMATICA WILL NOT BE LIABLE AND WILL TAKE NO
RESPONSIBILITY IN SUCH AN EVENT
IF THE PROCESSED MEDIA TENDS TO HARDEN OR STICK IN
THE WORKING CHAMBER, THE PRODUCT HAS TO BE
REMOVED COMPLETELY FROM THE WORKING CHAMBER
PAY ATTENTION THAT THE TEMPERATURE DIFFERENCE
BETWEEN ACTUAL TEMPERATURE OF THE WORKING
CHAMBER AND CLEANING TEMPERATURE IS KEPT TO A
MINIMUM

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
10
of
38
A TEMPERATURE SHOCK CAN DAMAGE STRUCTURAL
COMPONENTS
THE CLEANING LIQUID SHOULD BE COMPATIBLE WITH THE
PARTS WETTED BY THE PRODUCT
BEFORE CLEANING WITH SOLVENTS, CHECK THE
COMPATIBILITY BETWEEN THE SOLVENT AND THE MATERIAL
OF THE O-RINGS
ALL MAINTENANCE WORK HAS TO BE DONE BY
SPECIALISTS OR ENGINEERS
BEFORE STARTING THE DISASSEMBLY, ALL ELECTRICAL
PARTS HAVE TO BE DISCONNECTED
BE SURE THAT THE MOTOR CANNOT BE STARTED FROM
ANOTHER PERSON, WHILE YOU ARE WORKING
CRANES AND/OR LIFTING EQUIPMENT MUST BE USED TO
MOVE AND TRANSPORT HEAVY MACHINERY

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
11
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ALL PARTS HAVE TO BE INSPECTED FOR SIGNS OF WEAR AND
DAMAGE AND, IF NECESSARY, THEY HAVE TO BE REPLACED
BEFORE REASSEMBLY, ALL SCREWS HAVE TO BE GREASED
NEVER GREASE THE SEALING FACES OF THE MECHANICAL
SEALS
RESIDUAL DANGERS
When the system/equipment is used in accordance with rules and regulations, resid-
ual dangers are minimal.
Residual danger
Countermeasures
Tripping over feed or re-
turn lines
This should be laid appropriately
Breakage of glass contain-
ers
Wear protective clothing (gog-
gles etc.)
Splashing of the product
Hearing loss due to loud
noise
According to the application,
ear protection must be used
Tilting of the device
Use stable, non-slip base

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
12
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38
List of Content
1INTRODUCTION ................................................................................................ 13
2DESCRIPTION OF THE EQUIPMENT................................................................... 14
2.1 DRIVE UNIT........................................................................................................................ 15
2.2 WORKING CHAMBER......................................................................................................... 16
2.2.1
DISPERSING GENERATORS ................................................................................................ 17
2.2.2 MECHANICAL SEAL............................................................................................................ 18
2.2.3 FITTINGS FOR PRODUCT INLET &OUTLET......................................................................... 19
3INSTALLATION AND START-UP ........................................................................ 20
3.1 INSTALLATION.................................................................................................................. 21
3.1.1
MECHANICAL INSTALLATION............................................................................................ 21
3.1.2 ELECTRICAL INSTALLATION .............................................................................................. 22
3.2 START-UP ......................................................................................................................... 22
3.3 SHUT-DOWN .................................................................................................................... 25
3.4 CLEANING......................................................................................................................... 26
4MAINTENANCE WORK ...................................................................................... 27
4.1 MAINTENANCE AND INSPECTION PLAN ............................................................................ 27
4.2 DISASSEMBLY AND ASSEMBLY OF STANDARD WORKING CHAMBER .................................28
4.2.1
REPLACEMENT OF THE MECHANICAL SEAL ....................................................................... 29
4.2.2 REPLACEMENT OF THE BALL BEARINGS ............................................................................30
4.2.3 REPLACEMENT OF THE SHAFT SEALING RING....................................................................30
4.2.4 RESTART OF THE SYSTEM AFTER MAINTENANCE ..............................................................30
5SPARE PARTS..................................................................................................... 31
5.1 ORDERING OF SPARE PARTS ............................................................................................. 31
5.2 RECOMMENDED SPARE PARTS.......................................................................................... 31
6FAULTS AND REMEDIES..................................................................................... 32
7TECHNICAL DATA ............................................................................................. 33
7.1 DRIVE UNITS...................................................................................................................... 33
7.2 WORKING CHAMBERS .......................................................................................................34
7.3 QUENCH SYSTEMS ............................................................................................................ 35
7.5 DISPERSING GENERATORS ................................................................................................ 36
7.6 FITTINGS FOR PRODUCT INLET &OUTLET......................................................................... 37
8WARRANTY ....................................................................................................... 38

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
13
of
38
1INTRODUCTION
KINEMATICA is a specialist for design and manufacturing of dispersing and mixing
machines. The aim of this document is to instruct new users in the effective and safe
utilization of our equipment.
The KINEMATICA Inline homogenizing system MEGATRON®MT 5100 S² has been
designed and manufactured according the CE guidelines, the actual technical
standards and applicable safety rules and is marked with the CE mark.
This document is valid for the KINEMATICA Inline homogenizing system
MEGATRON®MT 5100 S².
The system is designed and manufactured for the intended application consisting of:
•In-Line processing of flowable and pumpable products under the considera-
tions and limitations given in the “Technical Data”.
•The processed media must be compatible with all constructional parts wetted
by the product.
•If suitable precautions to personnel are taken to prevent any harm due to
noise emission.
•The use of the system with no structural, mechanical or electrical changes dif-
ferent from the original scope of supply.
Typical applications:
•Preparing emulsions
•Pharmaceutical or cosmetics products
•Suspending solids in liquids (such as liquid polymers)
•Dispersing fine solids in liquids or molten phases
•Suspending additives and solid polymers in mineral oils
•Extracting enzymes from biomass
•Extracting active ingredients and substances from plants, for example (when
used with REACTRON®)
•Grinding and shredding of solids and fibers in liquids or polymers
If the system is used for purposes different than or over and above the capabilities
specified herein, KINEMATICA does not guarantee proper function and assumes no
obligation or liability.
Should you have any questions which are not answered in this document, please
contact KINEMATICA.
Check on www.kinematica.ch for your closest contact address.

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
14
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2DESCRIPTION OF THE EQUIPMENT
For a ready-to-use system you need:
•Drive unit MEGATRON® MT 5100 S²
•A working chamber MTO/MTK 5100 Q
•A recirculation system (can also be supplied by the customer)
Drive Unit
Working
Chamber
Example of a customized and
extended recirculation system

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
15
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2.1 DRIVE UNIT
The drive unit contains the powerful three-phase high frequency motor (with quick
coupling for the working chamber) controlled by the integrated VFD installed in a
stainless steel housing.
Main Switch
On/Off
Control panel
with Display
Quick coupling
for the working
chamber
Stop button
Start button
Speed Down
Speed Up
Enter Programming
Mode VFD
Speed
Display

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
16
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38
2.2 WORKING CHAMBER
The working chamber is a flow through in line chamber.
The working chamber consists of the following general parts:
•Bearing
•Mechanical sealing
•Inner chamber with dispersing generator and product inlet/outlet connections
•Cooling/Heating jacket if applicable
Product
Inlet
Product
Outlet
Cooling/Heating Jacket
(optional)
Dispersing
Generator
Coupling /
Bearing
Mechanical
Seal

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
17
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38
2.2.1 DISPERSING GENERATORS
A dispersing generator consists of a rotor and a stator. Rotor and stator consists of
one or more teeth rows each for different levels of fineness.
Turning with high speed, the rotor creates inside the stator high mechanical shear
forces and shear stress resulting in size reduction and turbulent mixing of the pro-
cessed media.
The generators are exchangeable with different types for different particle sizes.
Please bear in mind due to operation the dispersing generator(s) belong to the wear
and tear parts.
Rotor
Stator
Teeth / Teeth
row(s)

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
18
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38
2.2.2 MECHANICAL SEAL
The product side of the working chamber (inner chamber with dispersing generator)
has to be separated from the non-product or atmospheric side of the working cham-
ber. For that purpose, a single mechanical seal is installed inside the working cham-
ber.
The type and material combination of the mechanical seal have been chosen for the
application described in the contract and should therefore not be used for other pur-
poses without the permission of the manufacturer.
A mechanical seal is not allowed to run dry. Moreover, it has always to be lubricated,
flushed and cooled by a suitable sealing lubricant. The lubricant must also be com-
patible with the product and the materials of construction. The lubricant tempera-
ture has always to be 40°C below the boiling point to prevent any damages to the
sealing system.
In the case of a single mechanical seal, a pressureless quench liquid system (flow
through or pressureless tank) is used.
The standard working chambers for the MEGATRON®MT 5100 S² can be equipped
with a KINEMATICA quench system TS1 (also available with vessel made of PTFE)
Vessel Cover
Quench vessel
Standpipe
Quench outlet
Quench inlet

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
19
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IF YOU DO NOT USE A QUENCH SYSTEM TS1, YOU HAVE TO
CONNECT A FLOW-THROUGH, UNPRESSURIZED COOLING
LIQUID PIPING (E.G. TAP WATER) AND A FLOW RATE ≤ 1 L/MIN
2.2.3 FITTINGS FOR PRODUCT INLET & OUTLET
The standard inlet and outlet connections at the working chamber are inside thread
G1/2”.
Different standard fittings are available and can be screwed into the connections:
•Tri-Clamp ¾”
•Milk thread DN15
•Hose nipples DN15
G1/2”
G1/2”

INSTRUCTION MANUAL
System
MEGATRON®
Type
MT 5100 S2
Issue
3.0 / 01.07.2018
Page
20
of
38
3INSTALLATION AND START-UP
The drive unit MEGATRON®MT 5100 S² will be delivered completely assembled and
the package will include:
•Drive unit
•Mains cable
•Manual
The working chamber will be delivered completely assembled and the package will
include:
•Working Chamber (as ordered, optional)
•Dispersing Generator (as ordered, optional)
•Quench System (as ordered, optional)
•Product inlet & outlet fittings (as ordered, optional)
•Cooling/heating jacket (as ordered, optional)
Other accessories or equipment will be packed separately and delivered as ordered.
Always check the delivery note and check immediately when unpacking the unit. Al-
ways report immediately any irregularities.