The Kinematica MEGATRON® MT 3100 S² is an inline homogenizing system designed for efficient and safe utilization in various applications, particularly in the pharmaceutical, cosmetics, and chemical industries. This document serves as an instruction manual, providing comprehensive details on its operation, technical specifications, and maintenance.
Function Description:
The MEGATRON® MT 3100 S² system is engineered for in-line processing of flowable and pumpable products. Its core function involves creating high mechanical shear forces and shear stress through a high-speed rotating rotor within a stator. This action results in size reduction and turbulent mixing of the processed media, making it suitable for preparing emulsions, suspending solids in liquids, dispersing fine solids in liquids or molten phases, and extracting active ingredients. The system is designed to operate under specific technical data considerations and limitations, ensuring compatibility with all constructional parts wetted by the product. It is crucial that the system is used without any structural, mechanical, or electrical changes from its original scope of supply to maintain proper function and safety.
Important Technical Specifications:
The MEGATRON® MT 3100 S² drive unit is a powerful three-phase high-frequency motor, controlled by an integrated Variable Frequency Drive (VFD), housed in a stainless-steel casing.
- Drive Unit:
- Motor Type: AC motor, 3-phase, gear-free direct drive.
- Supply Voltage: 1-phase, 230 V ~.
- Supply Frequency: 50-60 Hz.
- Max. Speed: 30,000 rpm (+/- 2%).
- Input Power: Max. 1,500 W.
- Output Power: Max. 1,200 W.
- Soft-start: Yes.
- Noise Emission (drive only): Lower than 62 dB(A).
- Direction of Rotation: Counter-clockwise, seen from front.
- Ambient Temperature: 0 - 40°C.
- Relative Humidity: 80% max. non-condensing.
- Standards: Manufactured according to EN / IEC regulations for EMC & SAFETY.
- Protection Type: IP 20.
- Max. Period of Continuous Operation: 100%.
- Coupling Type: F.
- Weight (drive only): 10.2 kg.
- Working Chambers (MTO 3100 Q / MTK 3100 Q):
- Stages: 1 (for one dispersing generator).
- Product Connections: G1/4" / Tube olive fittings Ø12/8.
- Cooling/Heating Jacket: Available (MTK 3100 Q has connections 2xG1/8").
- Max. Speed: 30,000 rpm.
- Working Temperature: Max. 90°C.
- Working Pressure: Max. 6 bar(g).
- Differential Pressure: Max. 2 bar(g) between product inlet-outlet.
- Working Pressure Jacket (MTK 3100 Q): Max. 4 bar (g).
- Mechanical Seal: Type 2031-010 QBV-G (Q=Silicon-Carbide / B=Carbon / V=Viton / G=Stainless Steel).
- Quench Connections: Yes, tube Ø8x1 / G1/8".
- Quench Vessel: Yes, Standard TS1, made from Plexiglas, incl. lid and seal.
- Quench Pressure: Pressureless (continuous or with quench vessel).
- Materials Wetted by the Product: Stainless steel 316 L, O-Rings/Gaskets made of Viton.
- Surface Finish: Electropolished.
- Surface Roughness: Product wetted parts Ra ≤ 1.6 µm.
- Product Requirements: Must be pumpable and not contain solid particles that may destroy the mechanical seal.
- Product Viscosity: Approx. 500 mPas (depending on temperature, pressure, and product properties).
- CIP/SIP/Autoclavable: No (standard versions). Other versions with autoclavable design available on request.
- Weight: Approx. 2.0 kg (MTO 3100 Q), Approx. 2.5 kg (MTK 3100 Q).
- Dispersing Generators (Examples):
- MTG 20/2 FFV (13031520): Rotor Ø 15.5 mm, Stator Ø 20 mm, Max. flow 5 l/min.
- MTG 30/2 M (13031530): Rotor Ø 24 mm, Stator Ø 30 mm, Max. flow 11 l/min.
- MTG 30/4 F (13031531): Rotor Ø 26 mm, Stator Ø 30 mm, Max. flow 7 l/min.
- MTG 30/4 FFV (13031532): Rotor Ø 26.5 mm, Stator Ø 30 mm, Max. flow 6 l/min.
- All generators share Max. speed 30,000 rpm, Stainless steel 316 L materials, Electropolished surface finish (Ra 1.6 µm), and are sterilizable and autoclavable by common methods.
Usage Features:
The MEGATRON® MT 3100 S² is designed for ease of use with a control panel and display on the drive unit.
- Installation: The drive unit should be placed on an even surface, ensuring no vibrations are transmitted and sufficient air circulation is available. The working chamber connects to the drive unit via a quick coupling, requiring a simple push-back of the slide ring to fit or remove. Product inlet and outlet lines, along with necessary supply lines (e.g., cooling water, sealing liquid), must be connected, ensuring seals are used to prevent leakages and that piping does not exert forces on the working chamber nozzles.
- Electrical Installation: Before connecting to the electrical power supply, users must verify that the "Technical Data" and the drive tag plate data match.
- Start-Up: Prior to operation, all connections and piping must be checked for tightness. The quench system must be filled with a compatible sealing liquid, ensuring the standpipe is always covered to prevent mechanical seal damage. The product piping must be free of air pockets. The unit is started by pushing the On/Off button, followed by the green RUN "I" button. Speed can be adjusted using Up/Down buttons. The display shows motor speed (rpm), motor current (A), and output frequency (Hz).
- Shut-Down: To stop the unit, the speed should be decreased to "0" or "Standby" using the Down button, then the red "Stop" button is pressed. Alternatively, the "Stop" button can be pressed directly to halt the unit, and pressing "RUN" again will return it to the last set speed (Pause-Mode). Finally, the On/Off button is pushed to shut down the system completely, and inlet/outlet circuits are closed.
- Cleaning: The working chamber must be cleaned after every use, especially if processed media tends to harden or stick. Cleaning can involve pushing out product under pressure (not exceeding normal working pressure) or disassembling the working chamber.
- Language Change: The display language can be changed by holding the Start, Navigate, and Up keys for more than 1 second, then using the Up/Down arrows to select a language, and pressing Navigate to confirm.
Maintenance Features:
The MEGATRON® MT 3100 S² is designed for minimal maintenance, but regular checks and part replacements are essential for a long lifespan.
- Maintenance and Inspection Plan: Regular inspections are crucial for optimum and safe operation.
- Daily Inspection Work: Check for leakage of sealant fluid, piping system leakage, overheated bearing housing, high noise levels, unusual noises, or foreign bodies in the working chamber. Any irregularities require immediate shutdown and repair.
- Yearly Inspection Work or Every 3000 Running Hours: Inspect for signs of wear or deformation of the generator, wear and damage on the mechanical seal, and replace ball bearings.
- Spare Parts: Only original Kinematica spare parts should be used. Recommended spare parts to keep on stock include mechanical seals, ball bearings, O-rings, shafts, and dispersing generators, as some components may have lead times of several weeks.
- Disassembly and Assembly of Standard Working Chamber: Detailed procedures are provided for disassembling and assembling the working chamber, including steps for removing piping, flanges, stators, rotors, and mechanical seals. Specific instructions are given for handling O-rings, shaft seals, and ball bearings.
- Replacement of Mechanical Seal: Mechanical seals must be replaced as a complete set. It is critical to ensure the spring is in the correct position and that the slide areas are clean and free of solid particles to prevent damage. Never grease the sealing faces or rotating rings of the mechanical seals.
- Replacement of Ball Bearings: New ball bearings should be heated to 120°C (not exceeding 130°C) before mounting on the shaft to facilitate easy installation. Used ball bearings should be disposed of and not reinstalled.
- Replacement of Shaft Sealing Ring: The shaft sealing ring (16) must be greased before mounting, ensuring the grease is compatible with the application and product. Mineral oil-based grease should not be used with EPDM sealings.
- Restart of the System After Maintenance: After reassembly, the system should be tested with water before processing real product to ensure correct function.
- Warranty: Kinematica AG offers a 24-month warranty against material or manufacturing faults. An additional 12-month warranty extension is provided upon registration within 20 days of receiving the device, extending the total warranty period to 36 months. The warranty is void if modifications are made by unauthorized personnel, or if damage results from non-compliance with operating instructions, carelessness, accident, incorrect use, or incorrect supply voltage.
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