高压均质机说明书-ATS,AH100D

ATSEngineeringInc.OWNER’SMANUALAH100DAttention1.Toavoidtheparticlesofimpurities(suchasiron,glass,othehomogenizertowearinletvalveandhomogenizingvalve,everymaterielshouldbefilteredbyfilterscreenof60-100mubeforeitisputintohomogenizertohomogenized.2.Itisforbiddentooperatemachinelongtimewhenthereisnomaterial3.Donotturnonhomogenizerunderhandlewastightly,forsuddenoverloadcapacitywilldamagemotor.4.AH08-100homogenizerisdesignedforproduction.Themachinecanworkforalongtime.5.Solidceramicplungerusedforhomogenizer.Sothetemperaturechangesofproductcontactpiecescouldn’tover70℃,ortheplungermayrupture.Therangeoftemperaturechangesshouldn’tover5℃,especiallyundercleaningoperation.1ThetheoryofHomogenization1.1WhatishomogenizationHomogenizationisfinishedbyhomogenizingvalveandpistonwhichcanrefinethematerialoccurredinthehomogeneousvalveandmixthem.1.2ThetheoryofhomogenizationMaterialisinhaledthroughthepiston.Withthehelpoftheplunger,itcanenterthegap.Also,thesizeofthegapischangingwithdifferentpressures.Releasingthepressure,thematerialejectwiththespeedofonethousandtoonethousandandfivehundredmeterspersecond.Threeeffectsproducedafterthematerialhittheimpactringwhichisoneofthevalvecomponents.HoleeffectThematerialaccumulatedhighenergyafterpressedbytheplunger.Whenpassingthelimitinggap,itcanreleasehighenergyafterthesuddendecreasingofpressure.Throughit,thematerialcanbesmashedandrefined.ThisiscalledHoleeffect.ImpacteffectWhenpassingthelimitinggap,thematerialsmashedandrefinedafterhittingthespecialimpactring.SheareffectThehighspeedingmaterialproducestrongshearingwhencrossingthevalvechamberchannelandlimitinggap.1.3Functiondiagramofplungerpump1.4Functiondiagramofhomogeneousvalve1.5Functiondiagramoftwostageshomogeneousvalves2Introductionofequipmentstructure2.1Pressureblock1-stainlessinletcup6-inletpipe2-inletvalveplunger7-outletpipe3-outletvalveplunger8-pressureblock4-pressuregauge9-thefirststagevalve5-thesecondstagevalve2.2ceramicplunger1-solidceramicplunger2-locknut3-tensionring4-spacerring-plungerseal2.3inletvalve1.fixednut2.fixedplug3.gasket4.o-ring5.spring6.ceramicball7.inletvalveseatPressureblockwasmadeoftwo-phasealloysstainlesssteel.Toensureequipmentworkwellunderhighpressureandeasilyremovalandinstallation.Theinternalpipesizeofpressureblockis12ml.Atleast50mlmaterialcanbeoperatedcircularlywiththespecialfeeder.Installationwithpressureblock:√Asolidceramicplunger,whichhassmoothsurfaceandhighcorrosion-resistantthatself-lubricating.√Specialmaterialofplungerseal.Itcanbeusedwithnowaterlubrication.√Unidirectionalinletvalveandoutletvalve.Avalvesupportwasbeinstalledunderinletvalvewhichcanberemoval.InletvalveismadeofalloyswithhighhardnessSTELLITE√Adigtalgaugeofhighprecisionwhichadoptedsanitarydesignandwithbattery.2.4homogeneousvalvegroup1-homogenousvalvebody2-O-ring3-InsideO-ring4-OutsideO-ring5-MandrilO-ring6-Mandril7-HandleAsetvalvewasinstalledinvalvebodybyrotatinghandletopushmandriltochangepressure.Theyformedastandardhomogenousvalvegroup.2.5homogeneousvalveWesuppliedtwosetsofhomogeneousvalvesforAH100D.Onesetemulsionvalveandonesetrupturevalve.Emulsionvalveisformedbyoneceramicball,onestainlesscollisionringandonetungstencarbidevalveseat.Bothsidesofvalveseatcanbeused,soitcanbeusedforamoretime.Emulsionvalveusuallyusedforpreparationofemulsion,forexample,Chemicalandpharmaceutical:vitaminemulsion,veinemulsionFoodandbeverage:essence,juice,vegetableproteinbeverageDairyproducts:milk,icecream,cream,yogurtRupturevalveisformedbyoneimpacthead,onevalveseatandoneimpactring.Theyaremadeoftungstencarbide.2.6TechnicalparametersoftheequipmentModel:AH100DCapacity:8-15L/HMaximumoperatingpressure:1800barStrokeofequipment:98-184times/minMaximumviscosity:2000CpMaximumtemperatureoftheproduct:90℃Maximumtemperatureofthesteam:121℃3.EquipmentOperation3.1.Checkbeforestart1.ATShigh-pressuredhomogenizerisdesignedtoreachveryhighpressure,therefore,goodoperationalhabitcanpreventandavoidinjuries&harmtodeviceitself.2.Inordertousethisequipmentaccuratelyandsafely,operatorsareaskedtomakeregularandnecessaryinspection,makesurethattheequipmentworksinidealconditionandpreventanypossibleproblems.Note:Makesurenometalparticlesinhomogenizingorbrokenmaterialfluid.3.MakesurethatboltsontheFlan,differentconnectingandpressuremassaretotallytightened.4.Putupthepowerlineandturnonthemainpower.5.Checktherotationaldirectionofmotor.Makesurethatfanrotatesinthedirectionofthearrow.Note:Ifthedirectionofmotorisnotconsistentwiththedirectionofthearrow,pleaseadjusttheconnectionontheelectricplug.6.Checkmanifoldsassemblecorrectornot,manifoldswasherswellornot,iftheyarecorrectandwell,thenyoucanreconfiguremanifolds.7.Makesurethattwostageshomogenizingvalvehandwheelsaretotallyloosened,butnottooloosen.8.Presstheswitchofpressuregaugeandconfirmthevalueiszero.9.Checkthering&pistonsealperiodicallytomakeitleak-off.3.2Turnontheequipment1.Addsomewaterintotheinletcup.2.Makesurehandleislooseandpressuregaugeshowsthereisnopressure.3.Rotatetheswitch,andthentheequipmentcanbegintowork.Accordingtotherequiredcapacitytoadjustconverterknobslowly,untilitreachaappropriatefrequencyandthedischargeiswell-distributedandcontinuous,withoutabnormalnoise.4.Whenthevalueofpressureiszero,youcanswitchofftheequipment.Note:Ifthere’snomaterialfluiddischargedfromtheoutletafteryouturnontheequipmentfor60seconds,itindicatesthatairblockingexistedinthepressuremass.Ifso,youshouldswitchofftheequipmentfirstly,turnonthechargingvalveanddivertmaterialfluidintopressuremass,thenturnonequipmentagain3.3PressureadjustmentFirst-stageadjustmentRotatehandleclockwisetoincreasepressure,androtatewiddershinstodecrease.Maxpressureis1800bar.Pressureincreased:1Adjustthepressureofsecond-stagevalve:rotatehandlewiddershinsandslowlytoincreasethepressuretorequirement.2Adjustthepressureoffirst-stage:rotatehandleclockwiseandslowlytoincreasethepressuretothetotalpressure.Remarks:itisanormalconditionthatthenoiseisincreasedbytheincreasedpressure.Pressuredischarged:1dischargepressureofthefirst-stagehomogeneousvalve:Rotatehandlewiddershinsandslowlytodecreasethepressuretothepressureofthesecond-stage,thenstoprotating.2Dischargepressureofthesecond-stagehomogeneousvalve:Rotatehandlewiddershinsandslowlyuntilthepressurewasdecreasedtozero,thenstoprotating.Attention:stoprotatinguntilthepressureiszero,donotrotatetooloose.3.4Operationalprocedure1.Putsomewaterintotheinletcup,turnonequipment.2.Adjustthepressuretotherequirement.3.Don’tputmaterialintotheinletcupuntilwaterflowedtothebottomofthecup.4.Attheprocessofhomogenous,operatorshouldpayattentiontothematerialintheinletcup.5.whenfinishedoperating,pleasedischargematerialinequipment.Putsomewaterintoinletcup.6.Adjustthepressuretozero,thencleanequipmentasyourrequirement.7.Rotateswitchwiddershins,turnoff.3.5Cleaning1.Putclearwaterintoinletcupimmediatelywhentheoperatingmaterialisflowinginthebottomofthecup.Thenuse60℃watertoclean.2.200barpressurecanbeusedwhencleaningtheequipment.3.Suiteddetergent:NaOH:Maximumconsistency3%Maxtemperature90℃HNO3:Maximumconsistency0.5%Maxtemperature70℃H3PO4:Maximumconsistency3%Maxtemperature85℃Hotwater:Maxtemperature95℃Steam:Maxtemperature130℃Attention:Detergentisprohibittoincludetheelementofchlorineandiodine.3.6SterilizationoperationAH100Dhomogenizerwasdesignedtosterilizebypuresteam.Themaximumtemperatureofthepuresteamis121℃.Thelongesttimeofsterilizationis30min.Thehighestpressureofsterilizationis3.8bar.1.Opentheinletclamp,removetheinletcup.2.Steamproducerandinletflangeisconnectedbyclamp.3.Timeofsterilizationshouldnotover30min.Donotturnonequipmentontheprocessofsterilization.4.Naturecoolingaftersterilization.Donotcoolingbycoolwater.5.Disconnecttheconnectionofinletflangeafterthepressureblockiscooltotally.4Maintained4.1TodisassembleandassemblevalvesofInlet/OutletTodisassemble1.Usespannertoremovethefixedbolt1&22.Useextractortoremovefixationdevice3&43.Usetweezerstoremovespringandceramicballof5&6Toassemble1.Putceramicball5onopeningofoutletvalvebytweezers,andputceramicball6oninletvalveseat.Makesuretheyareinmiddleposition.2.Tofixspringonfixationdevice3&4.Totightenfixedblot1&2byspanner.4.2TodisassembleandassemblethepressuregaugeTodisassembleLoosenboltsandremovethepressuregauge1.Donotpulltheheadofthegauge.Pleaseholdthebodyofthegauge.Toassemble1.Putgasket2belowpressuregauge,theninstallo-ring3.2.Putthegaugeintohole,thenfixbolts.4.3TodisassembleandassemblehomogeneousvalveTodisassembleandinspect1.Loosenboltofvalve,removethewholevalve.2.Pressvalveseatandrotatehandleclockwisetopushoutvalvegroupandmandril7.3.Checkthesurfaceofhomogeneousvalveseatandimpactheadorring.Toassemble1.LubricateallO-ringsbyfoodgradegreasebeforeassembleallproducts.2.Toputhandle8intovalve4byrotatingclockwise.3.Putimpactheadintovalve,thenputimpactring,atlastputvalveseatintovalve.4.Putwettinggasket2attachedtothesurfaceofvalveseat.5.Checkoutifthereisgasketintheholeofthefirst-stagevalve,thenputitintovalvebodyandfixthebolts.6.Toassemblethesecond-stagevalveisthesameprogressasthefirst-stage.4.4TodisassembleandassemblethepressureblockTodisassemble1.Removethefixedbolt1byspannerof24#2.Holdpressureblock2topullitoutgently,thenremovepressureblock.Theweightofpressureblockis20KG.3.Remove