INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 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...
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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...
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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...
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INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 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...
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INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 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...
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INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 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...
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INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 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...
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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...
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INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 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...
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INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 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...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page List of Content 1 INTRODUCTION ....................13 2 DESCRIPTION OF THE EQUIPMENT ..............14 DRIVE UNIT ........................15 WORKING CHAMBER ......................16 2.2.1 DISPERSING GENERATORS ....................17 2.2.2 MECHANICAL SEAL ......................
3.0 / 01.07.2018 Page 1 INTRODUCTION 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...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 2 DESCRIPTION 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...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 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.
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 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 •...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 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. Rotor Stator Teeth / Teeth...
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...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 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 &...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 3 INSTALLATION AND START-UP The drive unit MEGATRON MT 5100 S² will be delivered completely assembled and ® the package will include: • Drive unit • Mains cable •...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 3.1 INSTALLATION 3.1.1 MECHANICAL INSTALLATION • The MEGATRON has to be positioned on an even surface or foundation. En- ® sure that no vibrations can be transmitted onto the MEGATRON .
• The sealing liquid has to be compatible with the product, the seals and the mechanical seal. The sealing liquid is not within the scope of supply of KINEMATICA. • Use enough sealing liquid so that the standpipe is always covered. Otherwise the mechanical seal will be damaged.
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INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page • Open the inlet and outlet product circuits. • Check all connections, piping and supply lines for signs of leakage. • The piping containing the product to be processed must be free of air pockets and air enclosures.
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INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page • Then push the green RUN “I” button in order to start the unit. The unit will in- crease the speed to the last set speed. Speed indication •...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 3.3 SHUT-DOWN • Use the Down buttons to decrease the speed to “0”. • Push the red STOP “O” button to stop the unit. INFO: It is also possible to push the red STOP “O” button to stop the unit without decreasing the speed first.
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page • Push the On/Off button. In OFF position, the light of the main switch and speed display will vanish and the system will shut down. • Finally, close the inlet and outlet circuits if applicable 3.4 CLEANING •...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 4 MAINTENANCE WORK • The MEGATRON MT 5100 S² drive unit is designed to be almost mainte- ® nance-free. Nevertheless to guarantee a long lifetime the unit should always be used with care.
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 4.2 DISASSEMBLY AND ASSEMBLY OF STANDARD WORKING CHAMBER This procedure is valid for the working chamber MTO 5100 Q (23005017). Before demounting, please drain the working chamber completely and remove the quench connections.
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page • Push the shaft (7) with ball bearings (19, 18) out of the bearing housing (1) into direction of the generator. • If necessary, remove the locking ring (21) and the compensation disc (22) from the bearing housing (1).
SINGLE PARTS. WE RECOMMEND TO TAKE A WHOLE NEW SPARE MECHANICAL SEAL AND SEND THE DAMAGED ONE BACK TO THE NEAREST KINEMATICA REPRESENTATIVE 4.2.2 REPLACEMENT OF THE BALL BEARINGS To put on new ball bearings (18,19) on the shaft, they must be heat up to 120 °C (not more than 130°C).
Issue 3.0 / 01.07.2018 Page 5 SPARE PARTS Only original KINEMATICA spare parts will guarantee a trouble free operation of the machine. See also the “Technical Data Sheet” and the referenced documentation, drawings and parts lists. 5.1 ORDERING OF SPARE PARTS when ordering spare parts, please indicate: Type of machine (e.g.
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 6 FAULTS AND REMEDIES Fault Possible causes Remedy Noise in the bearing Dusty, dirty or damaged Replace the bearings housing bearings Foreign body in working Rattle noise Remove foreign body chamber Twisted shaft...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 7 TECHNICAL DATA 7.1 DRIVE UNITS Description Drive Unit MEGATRON MT 5100 S² ® Order Code 23005060 23005061 23005062 23005063 Plug type motor type AC motor 3-phase, gearfree direct drive supply voltage 1-phase, 230 V ~ supply frequency...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 7.5 DISPERSING GENERATORS Dispersing generators MTG ../. X Order code Type 30/2 M 30/4 F 40/2 G 40/4 M 40/6 F 40/6 FV 40/6 FF 40/6 FFV Rotor Ø...
INSTRUCTION MANUAL System MEGATRON ® Type MT 5100 S Issue 3.0 / 01.07.2018 Page 7.6 FITTINGS FOR PRODUCT INLET & OUTLET Description Order no. Hose nipple DN15 (set of 2) 23005022 Milk thread DN 15 according to DIN 11851 23005023 (set of 2) Tri-Clamp ¾”...
24 months. KINEMATICA will repair or replace and return free of charge any part which is re- turned to its factory within said period, transportation prepaid by the user and which is found upon inspection to have been defective in materials or workmanship.
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