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Summary of Contents for Microfluidics MICROFLUIDIZER LV1 Series
- Page 1 MODEL LV1 SERIES ® MICROFLUIDIZER PROCESSOR User Manual 30 Ossipee Rd P.O. Box 9101 Newton, MA 02464-9101 Phone 617-969-5452 Fax 617-965-1213 mixinginfo@mfics.com www.microfluidicscorp.com Part No. 85.0098...
- Page 2 Copyright © 2011 Microfluidics International Corporation. All rights reserved. This manual may not be copied, photocopied, reproduced, translated, converted to an electronic or machine- readable form in whole or in part, or distributed to customers or other third parties without prior written...
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Page 3: Model Lv1 Microfluidizer Processor Data Sheet
Model LV1 Microfluidizer Data Sheet Model LV1 Microfluidizer Processor Data Sheet Serial #: Customer: Intensifier Ratio: 21:1 (Hydraulic Pressure: Process Pressure) Process Piston Diameter: 0.437 in. (11.1 mm) Stroke Length: 2.50 in. (63.5 mm) Volume/Stroke: 0.375 in. (6 ml) Process Piston Seal: UHMWPE (Ultra High Molecular Weight) Gasket/O-rings: Viton (standard) - Page 4 Model LV1 Microfluidizer Data Sheet Model Number Oil Reservoir Capacity (Approximate) 2.5 liters (0.7 gallon) Motor Horse Power 0.37 kw (1/2 hp) Motor Data Voltage Amperage Phase Frequency 1800 RPM 110V 1 Phase 60 Hz 1800 RPM 208 - 1 Phase 60 Hz 230VAC 1400 RPM...
- Page 5 Revision Page Revision Page for LV1 This manual is Revision 10 for the LV1 Microfluidizer Processor and is dated September 7, 2011. It consists of the following chapter revisions: Chapter Revision Code Forward Data Sheet F-LV-1-5 8/3/2011 Chapter 1: Introduction 1-LV-1-2 12/28/2010 Chapter 2: Overview 2-LV-1-5 8/3/11...
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Page 6: Table Of Contents
Table of Contents Table of Contents Table of Contents ....................TOC-1 Model LV1 Microfluidizer Processor Data Sheet ............F-1 Intensifier ....................F-1 Interaction Chamber ..................F-1 Model Specifications ..................F-1 Revision Page for LV1; Revision 3 ................REV-1 Chapter 1: Introduction..................1-1 Inside this Manual .................. - Page 7 Table of Contents Operating the Equipment ................3-9 Filling the Product Inlet Reservoir .............. 3-9 Duty Cycle ....................3-11 Cleaning and Storing the Equipment ..............3-11 Using the Emergency Stop ................3-11 Chapter 4: Maintenance ..................4-1 Replacing Piston Seal Assembly ............... 4-1 Removing the Liquid End Body ..............
- Page 8 Table of Contents Mobil DTE 25 ..................... E-2 12/28/2010 LV1 User Manual TOC-3...
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Page 9: Chapter 1: Introduction
Disclaimers Due to design changes and product improvements, information in this manual is subject to change without notice. Microfluidics (hereafter called “MFIC”) reserves the right to change design at any time, which may subsequently affect the contents of this manual. -
Page 10: Warranty
Chapter 1: Introduction Warranty The sole warranty provided by the Company is contained in the "Microfluidics Corporation Standard Terms and Conditions", Form M-5 provided at time of purchase. 1-LV-1-2 12/28/2010 LV1 User Manual... -
Page 11: Chapter 2: Overview
Chapter 2: Overview Chapter 2: Overview Chapter 2 includes detailed information about the principle of operation, hydraulic power system, high pressure intensifier, interaction chamber, controls, and system specifications. General Description The LV1 Series Microfluidizer Processor is designed for high efficiency cell rupturing and high- performance micro-mixing of emulsions and dispersions in a variety of industries. -
Page 12: Hydraulic Power System
It is easily accessible for cleaning or replacing. Constructed of stainless steel with ceramic product contact surfaces, the interaction chamber is dimensionally fixed. Microfluidics supplies the interaction chamber in the correct size according to each customer’s product requirements and specifications. - Page 13 Chapter 2: Overview Figure 2.1. Front Panel Controls/Components Control/Component Name Description Green. Comes on when power is delivered to the unit. A. Power-On Light Green. Indicates it is OK to extend piston at high pressure. B. Ready Light Retracts piston in Jog mode only. C.
- Page 14 Chapter 2: Overview Control/Component Name Description Has a range from 0 to 40,000 psi. Note that the pressure being M. Process Pressure Gauge monitored is NOT product pressure, but scaled hydraulic pressure that represents the product process pressure. Allows delivery of power upon system initialization. N.
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Page 15: Chapter 3: Operation
Chapter 3: Operation Chapter 3: Operation Safety Warnings & Cautions "WARNING” indicates that if a specific procedure or practice is not followed correctly, bodily injury could occur. "CAUTION" indicates that if a specific procedure or practice is not observed, damage to the equipment could result. -
Page 16: System Description
Chapter 3: Operation THE TANK. DAMAGE TO THE PUMP COULD RESULT. DURING OIL FILL, EYE PROTECTION MUST BE WORN. WARNING: THE ACCUMULATOR MUST BE CHARGED BEFORE THE MACHINE CAN BE OPERATED. SEE SECTION ON ACCUMULATOR CHARGING. DURING CHARGING, EYE PROTECTION MUST BE WORN. -
Page 17: Items Not Supplied
Chapter 3: Operation Items Not Supplied The following items are NOT supplied with the unit: Compressed nitrogen @ 96.5 bar (1,400 psi) • External safety device on the feed supply or product discharge lines • Site Preparation NOTE: Check the shipping container and its contents for damage. If damage is suspected, notify both the carrier and MFIC immediately on the straight bill of lading (supplied by the carrier). -
Page 18: Foundation/Benchtop
Chapter 3: Operation Foundation/Benchtop The foundation or benchtop of the proposed operating site MUST be able to support the gross weight of the Microfluidizer equipment, including oil. Clearances A minimum clearance of 10 inches (25.4 cm) around all sides of the Microfluidizer equipment is required. -
Page 19: Information On Charging Accumulators
Chapter 3: Operation The LV1 is supplied with a motor starter that includes On/Off switching. The LV1 must be properly grounded according to national and local electrical codes. The end user must supply an electrical circuit breaker and disconnect for the LV1. All fuses and relays are located within the electrical box of the unit. - Page 20 Chapter 3: Operation 9. Let the pre-charge set for 10-15 minutes. This will allow the gas temperature to stabilize. If the desired pre-charge is exceeded, close the nitrogen bottle valve, and then slowly open the bleed valve (refer to Figure 3.2). CAUTION: DO NOT REDUCE THE PRE-CHARGE BY DEPRESSING THE VALVE CORE WITH A FOREIGN OBJECT.
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Page 21: Environmental Requirements
Chapter 3: Operation 2. Using the funnel and tube supplied in the tool kit, begin to slowly pour approximately 0.4 gallon (1.5 liters) slowly into the hydraulic reservoir. 3. Replace the fill/vent cap. 4. Operate the unit in JOG mode by retracting and extending the piston fully for 5-10 strokes in order to remove air in the hydraulic system. -
Page 22: Preparing For Use
Chapter 3: Operation 1. Turn the Mode switch to the Off position. 2. Turn the Process Pressure Control knob counterclockwise until it stops, then rotate 2 turns clockwise. NOTE: Before starting the LV1, the Emergency Stop knob has to be pulled out (by rotating it clockwise) and the blue Reset button on the control panel has to be depressed. -
Page 23: Operating The Equipment
Chapter 3: Operation 1. Turn on the Master Power On/Off switch at the rear of the LV1. 2. Press the blue Reset button located on the control panel. 3. Rotate the Mode switch to the Jog position. The motor should turn on. Press and hold the Extend button for about 15 seconds to fully extend the piston. -
Page 24: Filling The Product Inlet Reservoir
Chapter 3: Operation NOTE: Before starting the Microfluidizer processor, the Emergency Stop knob has to be pulled out by rotating it clockwise and the blue Reset button on the control panel has to be depressed. Filling the Product Inlet Reservoir 1. -
Page 25: Duty Cycle
Chapter 3: Operation WARNING: BE SURE THE PISTON OF THE OUTLET SYRINGE IS WELL INSIDE THE BORE OF THE SYRINGE ELSE IT MAY BE SHOT OUT AND INJURY MAY OCCUR. DO NOT ALLOW THE OUTLET SYRINGE TO OVERFILL! Duty Cycle The LV1 Processor was designed to process very limited volumes of fluid and as such has a limited duty cycle. - Page 26 Chapter 3: Operation 1. While the Microfluidizer processor is operating, press the Emergency Stop knob to stop the hydraulic cylinder and the motor. 2. To restart the Microfluidizer processor, reset the Emergency Stop knob by pulling it up and depressing the blue Reset button. Then, turn the Process Pressure Adjustment knob counterclockwise to set the process pressure to about 5000 psi.
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Page 27: Chapter 4: Maintenance
Chapter 4: Maintenance Chapter 4: Maintenance Chapter 4 provides user maintenance procedures organized by system component. Component categories include the hydraulic power system, hydraulic filters, switches, piston seal, hydraulic drive, hydraulic cylinder, tie-rods, check valves, and coned and threaded connections. A filter service schedule and hydraulic oil service schedule are included as well as procedures for making hydraulic adjustments. - Page 28 Chapter 4: Maintenance Access hole Access hole Figure 4.1 Access holes location Position two ¼” flat blade screwdrivers inside of the access holes and "pinch to rotate" the hydraulic cylinder extender (20) so that each of the two set screw holes (24) can be accessed by the access holes.
- Page 29 Chapter 4: Maintenance 9. Loosen the two set screws by applying some Never-Seez grease to the tip of an Alan wrench, and unscrew until they are very loose. The grease will prevent the screw from falling into the isolator. This will unhitch the piston (2) from the hydraulic cylinder extender (20).
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Page 30: Removing The Piston, Bearing Retainer And Bearing
Chapter 4: Maintenance Figure 4.4 Removal of the liquid end from the isolator The liquid end body should be allowed free access through the cutout at the bottom of the base plate. The isolator bearing (10) will come out with the liquid end body. A sliding hammer movement of the pump head on the piston may be necessary to pull out the isolator bearing. - Page 31 Chapter 4: Maintenance Figure 4.5 Removal of the bearing retainer using tool #801.13470 6. Loosen the bearing retainer and remove by sliding up onto the piston. 7. Pull out the piston from the liquid end body. The two backup rings (7) should remain on the piston.
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Page 32: Cleaning Components
(4). If such damage is found, the components must be replaced. For further assistance, contact the Customer Service Department at Microfluidics at 1-800-370-5452. Hours are 8:30 AM - 5:00 PM (EST) Monday through Friday. - Page 33 Chapter 4: Maintenance 1. Locate the piston (2) and slide the isolator bearing (10) with its external seals (15) (add internal seals (14) only with seal quench option). Make sure the screw holes on the isolator bearing face toward the seal end of the piston (2). 2.
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Page 34: Installing The Isolator (If Removed)
Chapter 4: Maintenance Figure 4.7 Piston assembled into liquid end body 15. Install the o-ring (13) onto the end of the piston (2) that fits into the extension (20). Installing the Isolator (If Removed) 1. Mount the isolator (3) by first lubricating the 1.5" diameter opening at the base with Tri- Clover spray or an equivalent lubricant. - Page 35 Chapter 4: Maintenance the set screws that fasten the piston can be accessed as in the Removing the Liquid End Body section of this chapter. 2. With the piston slightly pulled out of the bore of the liquid end, take the liquid end body with o-ring (15) and the 2.75"...
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Page 36: Check Valve Maintenance
Chapter 4: Maintenance 17. Fill the reservoir. 18. Re-prime the system 19. Check the system for leaks. Check Valve Maintenance The inlet check valve is located below the inlet tubing on the left of the Liquid end body. Its purpose is to allow flow into the pump during the suction stroke and to prevent back flow into the reservoir during the power stroke of the pump. -
Page 37: Outlet Valve Maintenance
With the exception of the suction strainer and the return line filter, repair or disassembly of the hydraulic components requires special tools and training. Call the Customer Service Department at Microfluidics at 1-800-370-5452 for further instructions. 4-LV-1-4 12/28/2010 LV1 User Manual... -
Page 38: Cleaning The Hydraulic Oil Reservoir & Servicing The Suction Strainer And Return Line Filter
Chapter 4: Maintenance Replace the hydraulic oil at one-year intervals, or test after every 500 hours of operation, and replace when necessary. Testing equipment, kits, and laboratory services are available through your local Parker Fluid Power Motion & Control Distributor. CAUTION: OIL MUST BE REPLACED IF IT BECOMES OVERHEATED (HOTTER THAN 140°F, 60°C) OR CONTAMINATED. -
Page 39: Return Filter Service Schedule
Excessive oil leaking from the isolator drain port nearest the stainless steel enclosure indicates that the hydraulic cylinder seals may need to be replaced. It is recommended that the hydraulic cylinder be factory serviced by Microfluidics technicians. Hydraulic Cylinder Disassembly 1. - Page 40 Chapter 4: Maintenance and remake the connection. For reference, see the Coned and Threaded Connection Drawing #B- 11028 on the CD. 4-LV-1-4 12/28/2010 LV1 User Manual 4-14...
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Page 41: Chapter 5: Troubleshooting
For a stubborn plug, sonicating the chamber in a solvent bath may help clear the blockage. If you are unable to clear the chamber, contact the Customer Service Department at Microfluidics at 1-800-370-5452. 5. Reverse steps 1 through 4 to return the unit back to normal operation. -
Page 42: Maintaining Connections And Fittings
Chapter 5: Troubleshooting CAUTION: ABRASIVE MATERIALS SHOULD NOT BE RUN THROUGH THE MICROFLUIDIZER UNLESS THE UNIT WAS SPECIFICALLY DESIGNED FOR SUCH AN APPLICATION. Maintaining Connections and Fittings All high pressure connections on the LV1 are coned and threaded connections. DO NOT use Teflon tape on the fittings. - Page 43 Chapter 5: Troubleshooting Symptom Possible Cause Remedy Directional control, Check fuse 1FU in Replace fuse if necessary extend, or retract does electrical box not respond Loose electrical Check and secure connections connection No hydraulic pressure Check hydraulic system pressure Symptom Possible Cause Remedy Overheating hydraulic...
- Page 44 Chapter 5: Troubleshooting Symptom Possible Cause Remedy Process pressure builds Plugged interaction chamber (IXC) but does not extend CAUTION: RELIEVE PRESSURE BY SWITCHING THE MODE SELECTOR TO THE OFF POSITION PRIOR TO TRYING ANY REMEDY. REVERSE THE POSITION OF THE IXC. RUN THE UNIT UNTIL THE PRODUCT FLOWS.
- Page 45 Reverse and back-flush the Is there process pressure? interaction chamber Check system pressure Remove and clean or replace switch. Call Microfluidics the Process Pressure Control Customer Service. Adjustment Valve cartridge Check relays CR1, CR2 5-LV-1-4 8/3/11 LV1 User Manual...
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Page 46: Motor Problems Table
Chapter 5: Troubleshooting Motor Problems Table Problem Check the Following (in Sequential Order) The motor stops or does Check that the Emergency Stop button is released not start Check that the “RESET” (blue button) is activated. Check the Master Power on/off switch circuit breaker Check 1FU fuse (located in the electrical box. -
Page 47: Appendix A: Drawing List
Appendix A: Drawing List Appendix A: Drawing List List of Drawings for LV1 The following drawings are included on the manual CD. LV1 Drawing # Description 801.00115 Inlet Outlet Piping Assembly LV1 801.00429 Liquid End Pump Assembly 801.00114 Outlet Valve Assembly LV1-UL Machine Outline 801.00456... -
Page 48: Appendix B: Tool & Spare Parts List
Appendix B: Tool & Spare Parts List Appendix B: Tool & Spare Parts List Standard Tool Kit Item Number Description LV1 60 Hz LV1 50 Hz 20.2045 Oil Hydraulic Mobil DTE 25 1.00 Gallon 15.1900 Gland, .13 HP SS 15.1901 Collar, .13 HP SS 15.1902 Plug, .13 HP SS... - Page 49 Appendix B: Tool & Spare Parts List Item Number Description LV1 60 Hz LV1 50 Hz 18.4013 Seal Piston LV1 18.4010 BU-ring for 110TYF Plunger Seal PEEK 18.4221 Plunger Bearing M-110EH 18.V014 O-ring #014 Viton 9005-75 2.0557 Fuse 4 Amp 5 x 20 mm Glass 48.8343 Washer, shim .373 OD x .253 ID 99.0428...
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Page 50: Appendix C: Options
Appendix C: Options Appendix C: Options Model LV1 Options Additional Interaction Chamber • Cooling Option - 12 inch • Cooling Option - 36 inch • Cooling Option -120 inch • Seal Quench • Fan Option Assembly • IQ/OQ Documentation • IQ/OQ Execution •... -
Page 51: Appendix D: Fluid Compatibility Tables
Appendix D: Fluid Compatibility Tables Appendix D: Fluid Compatibility Tables The following table is compiled primarily from data published by several manufacturers of elastomers and plastics. The ratings are intended only as a guide. In fact, different sources do not always agree, so it is best to test before committing to a particular compound. - Page 52 Appendix D: Fluid Compatibility Tables PEEK: Polyetheretherketone, one of the new high-strength engineering plastics. Has excellent chemical resistance and structural properties. Very high temperature capability. Used for bearings, gaskets, and back-up rings. PTFE: (Trade name, Teflon): Has broadest chemical resistance of all plastic materials and outstanding temperature capability. Limited strength and poor shape retention make PTFE a poor choice for sealing and load bearing applications unless combined with other fillers such as glass fibers, carbon graphite, or molybdenum disulfide.
- Page 53 Appendix D: Fluid Compatibility Tables Fluid Nitrile EPDM Neoprene Fluoroelastomer UHMWPE PEEK PTFE ASTM #1 ASTM #3 ASTM Fuel A ASTM Fuel B ASTM Fuel C ASTM Fuel D Auto Transmission Fluid Beer Benzaldehyde Benzene Benzoic Acid Benzophenone Benzyl Alcohol Bleach Borax Boric Acid...
- Page 54 Appendix D: Fluid Compatibility Tables Fluid Nitrile EPDM Neoprene Fluoroelastomer UHMWPE PEEK PTFE Carbitol Acetate Carbon Disulfide Carbon Tetrachloride Carbonic Acid Castor Oil Cellosolve Chassis Grease Chloroacetic Acid Chloroacetone Chlordane Chlorine Chlorobenzol Chloroform Chlorosulfonic Acid Chrome Plating Solution Chromic Acid Citric Acid Cod Liver Oil Coffee...
- Page 55 Appendix D: Fluid Compatibility Tables Fluid Nitrile EPDM Neoprene Fluoroelastomer UHMWPE PEEK PTFE Dichloroaniline Dichloro Butane Diesel Oil Diethylamine Diethyl Benzene Diethylene Glycol Dimethyl Ether Dimethyl Formamide Dimethyl Terephthalate Dioctyl Phthalate Dioxane Diphenyl Dow Corning 550 Dow Guard Dowtherm A & E Elco 28 Epoxy Resins Ethane...
- Page 56 Appendix D: Fluid Compatibility Tables Fluid Nitrile EPDM Neoprene Fluoroelastomer UHMWPE PEEK PTFE Ethylene Oxide Ferric Chloride Formaldehyde Formic Acid Freon 11 Freon 22 Freon 12 Fuel Oil Furan Furfural Furfuryl Alcohol Gallic Acid Gasoline Gelatin Glucose Glycerine Heptane Hexaldehyde Hexane Hexanol Home Heating Oil...
- Page 57 Appendix D: Fluid Compatibility Tables Fluid Nitrile EPDM Neoprene Fluoroelastomer UHMWPE PEEK PTFE Isopar Isopropanol Isopropyl Acetate JP-4 (MIL-J-5624) JP-5 (MIL-J-5624) Kerosene Lactic Acid Lacquers Lard Linoleic Acid Linseed Oil Lye Solutions Malathlon Maleic Acid Mercury Methane Methanol Methyl Acetate Methacrylic Acid Methyl Cellosolve Methylene Chloride...
- Page 58 Appendix D: Fluid Compatibility Tables Fluid Nitrile EPDM Neoprene Fluoroelastomer UHMWPE PEEK PTFE Natural Gas Neatsfoot Oil Nitric Acid Nitrobenzene Nitropropane Octane Octanol Oleic Acid Oleum Oxalic Acid Peanut Oil Pentane Perchloreothylene Petrolatum Petroleum Ether Phenol Phenylthydrazine Phosphoric Acid Pine Oil Potassium Hydroxide Propane Propanol...
- Page 59 Appendix D: Fluid Compatibility Tables Fluid Nitrile EPDM Neoprene Fluoroelastomer UHMWPE PEEK PTFE Skydrol Sodium Hydroxide Sodium Hypochlorite Sodium Peroxide Soy Bean Oil Stearic Acid Stoddard Solvent Styrene Monomer Sucrose Sulfuric Acid Tall Oil Tannic Acid Tartaric Acid Tetrachloroethane Tetrachloroethylene Tetraline Toluene Trichloroethylene...
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Page 60: Appendix E: Mobil Product Data Sheet
Appendix E: Mobil Product Data Sheet Appendix E: Mobil Product Data Sheet ® Mobil DTE 20 Series Super-Stabilized, Antiwear Hydraulic Oils Description Mobil DTE 20 Series high-quality hydraulic oils were developed in cooperation with pump and component manufacturers specifically for severe hydraulic systems using high-pressure, high- output pumps. -
Page 61: Health And Safety
Appendix E: Mobil Product Data Sheet Health and Safety Based on available toxicological information, these products produce no adverse effects on health when properly handled and used. No special precautions are suggested beyond attention to good personal hygiene, including laundering oil-soaked clothing and washing skin-contact areas with soap and water.
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