ATS Engineering Inc.OWNER’S MANUAL AH100DAttention1. To avoid the particles of impurities (such as iron, glass, etc.) into the homogenizer to wear inlet valve and homogenizing valve, every materiel should be filtered by filter screen of 60-100 mu before it is put into homogenizer to homogenized.2. It is forbidden to operate machine long time when there is no material3. Do not turn on homogenizer under handle was tightly, for sudden overload capacity will damage motor.4. AH08-100 homogenizer is designed for production. The machine can work for a long time.5. Solid ceramic plunger used for homogenizer. So the temperature changes of product contact pieces couldn’t over 70℃, or the plunger may rupture. The range of temperature changes shouldn’t over 5℃, especially under cleaning operation.1 The theory of Homogenization1.1 What is homogenizationHomogenization is finished by homogenizing valve and piston which can refine the material occurred in the homogeneous valve and mix them.1.2 The theory of homogenizationMaterial is inhaled through the piston. With the help of the plunger, it can enter the gap. Also, the size of the gap is changing with different pressures. Releasing the pressure, the material eject with the speed of one thousand to one thousand and five hundred meters per second. Three effects produced after the material hit the impact ring which is one of the valve components .Hole effectThe material accumulated high energy after pressed by the plunger. When passing the limiting gap, it can release high energy after the sudden decreasing of pressure. Through it , the material can be smashed and refined .This is called Hole effect.Impact effectWhen passing the limiting gap, the material smashed and refined after hitting the special impact ring.Shear effectThe high speeding material produce strong shearing when crossing the valve chamber channel and limiting gap.1.3 Function diagram of plunger pump1.4 Function diagram of homogeneous valve1.5 Function diagram of two stages homogeneous valves2Introduction of equipment structure2.1Pressure block1- stainless inlet cup 6- inlet pipe2- inlet valve plunger 7- outlet pipe3- outlet valve plunger 8- pressure block4- pressure gauge 9- the first stage valve 5- the second stage valve2.2ceramic plunger1- solid ceramic plunger 2- locknut3- tension ring 4- spacer ring- plunger seal2.3inlet valve1.fixed nut2.fixed plug3.gasket4.o-ring5.spring6.ceramicball7.inlet valveseatPressure block was made of two-phase alloys stainless steel. To ensure equipment work well under high pressure and easily removal and installation. The internal pipe size of pressure block is 12ml. At least 50ml material can be operated circularly with the special feeder.Installation with pressure block:√A solid ceramic plunger, which has smooth surface and high corrosion-resistant that self-lubricating.√Special material of plunger seal. It can be used with no water lubrication.√Unidirectional inlet valve and outlet valve. A valve support was be installed under inlet valve which can be removal. Inlet valve is made of alloys with high hardness STELLITE√A digtal gauge of high precision which adopted sanitary design and with battery.2.4homogeneous valve group1-homogenous valve body2-O-ring3-Inside O-ring4-Outside O-ring5-Mandril O-ring6-Mandril7-HandleA set valve was installed in valve body by rotating handle to push mandril to change pressure. They formed a standard homogenous valve group.2.5homogeneous valveWe supplied two sets of homogeneous valves for AH100D. One set emulsion valve and one set rupture valve.Emulsion valve is formed by one ceramic ball, one stainless collision ring and one tungsten carbide valve seat. Both sides of valve seat can be used, so it can be used for a more time.Emulsion valve usually used for preparation of emulsion, for example, Chemical and pharmaceutical : vitamin emulsion, vein emulsionFood and beverage: essence，juice，vegetable protein beverageDairy products: milk, ice cream， cream， yogurtRupture valve is formed by one impact head, one valve seat and one impact ring. They are made of tungsten carbide.2.6Technical parameters of the equipment Model: AH100DCapacity: 8-15L/HMaximum operating pressure: 1800barStroke of equipment: 98-184 times/min Maximum viscosity: 2000CpMaximum temperature of the product: 90℃Maximum temperature of the steam： 121℃3. Equipment Operation3.1. Check before start1. ATS high-pressured homogenizer is designed to reach very high pressure,therefore, good operational habit can prevent and avoid injuries & harm to device itself.2. In order to use this equipment accurately and safely, operators are asked to make regular and necessary inspection, make sure that the equipment works in ideal condition and prevent any possible problems.Note: Make sure no metal particles in homogenizing or broken material fluid.3. Make sure that bolts on the Flan, different connecting and pressure mass are totally tightened.4. Put up the power line and turn on the main power.5. Check the rotational direction of motor. Make sure that fan rotates in the direction of the arrow.Note: If the direction of motor is not consistent with the direction of the arrow, please adjust the connection on the electric plug.6. Check manifolds assemble correct or not, manifolds washers well or not, if they are correct and well, then you can reconfigure manifolds.7. Make sure that two stages homogenizing valve hand wheels are totallyloosened, but not too loosen.8. Press the switch of pressure gauge and confirm the value is zero.9.Check the ring & piston seal periodically to make it leak-off.3.2 Turn on the equipment1. Add some water into the inlet cup.2. Make sure handle is loose and pressure gauge shows there is no pressure.3. Rotate the switch, and then the equipment can begin to work. According to the required capacity to adjust converter knob slowly, until it reach a appropriate frequency and the discharge is well-distributed and continuous, without abnormal noise.4. When the value of pressure is zero, you can switch off the equipment. Note: If there’s no material fluid discharged from the outlet after you turn on the equipment for 60 seconds, it indicates that air blocking existed in the pressure mass. If so, you should switch off the equipment firstly, turn on the charging valve and divert material fluid into pressure mass, then turn on equipment again3.3 Pressure adjustmentThe second-stage pressureadjustment.Rotate handle clockwise toincrease pressure, and rotatewiddershins to decrease.First-stage adjustmentRotate handle clockwise toincrease pressure, and rotatewiddershins to decrease.Max pressure is 1800bar.Pressure increased:1)Adjust the pressure of second-stage valve: rotate handle widdershins andslowly to increase the pressure to requirement.2)Adjust the pressure of first-stage: rotate handle clockwise and slowly toincrease the pressure to the total pressure.Remarks: it is a normal condition that the noise is increased by the increased pressure.Pressure discharged:1)discharge pressure of the first-stage homogeneous valve: Rotate handlewiddershins and slowly to decrease the pressure to the pressure of the second-stage, then stop rotating.2)Discharge pressure of the second-stage homogeneous valve: Rotate handlewiddershins and slowly until the pressure was decreased to zero, then stop rotating.Attention: stop rotating until the pressure is zero, do not rotate too loose.3.4 Operational procedure1. Put some water into the inlet cup, turn on equipment.2. Adjust the pressure to the requirement.3. Don’t put material into the inlet cup until water flowed to the bottom of the cup.4. At the process of homogenous, operator should pay attention to the material in the inlet cup.5. when finished operating, please discharge material in equipment. Put some water into inlet cup.6. Adjust the pressure to zero, then clean equipment as your requirement.7. Rotate switch widdershins, turn off.3.5 Cleaning1.Put clear water into inlet cup immediately when the operating material is flowing in the bottom of the cup. Then use 60℃water to clean.2.200bar pressure can be used when cleaning the equipment.3.Suited detergent:NaOH : Maximum consistency 3% Max temperature 90℃HNO3 ：Maximum consistency 0.5% Max temperature 70℃H3PO4 : Maximum consistency 3% Max temperature 85℃Hot water: Max temperature 95℃Steam : Max temperature 130℃Attention: Detergent is prohibit to include the element of chlorine and iodine.3.6 Sterilization operationAH100D homogenizer was designed to sterilize by pure steam. The maximum temperature of the pure steam is 121℃. The longest time of sterilization is 30min. The highest pressure of sterilization is 3.8bar.1.Open the inlet clamp, remove the inlet cup.2.Steam producer and inlet flange is connected by clamp.3.Time of sterilization should not over 30min. Do not turn on equipment onthe process of sterilization.4.Nature cooling after sterilization. Do not cooling by cool water.5.Disconnect the connection of inlet flange after the pressure block is cooltotally.4 Maintained4.1 To disassemble and assemble valves of Inlet/ OutletTo disassemblee spanner to remove the fixed bolt 1&2e extractor to remove fixation device 3&4e tweezers to remove spring and ceramic ball of 5&6To assemble1.Put ceramic ball 5 on opening of outlet valve by tweezers, and put ceramicball 6 on inlet valve seat. Make sure they are in middle position.2.To fix spring on fixation device 3&4. To tighten fixed blot 1&2 by spanner.4.2 To disassemble and assemble the pressure gaugeTo disassembleLoosen bolts and remove the pressure gauge 1. Do not pull the head of the gauge. Please hold the body of the gauge.To assemble1.Put gasket 2 below pressure gauge, then install o-ring 3.2.Put the gauge into hole, then fix bolts.4.3 To disassemble and assemble homogeneous valveTo disassemble and inspect1.Loosen bolt of valve, remove the whole valve.2.Press valve seat and rotate handle clockwise to push out valve group andmandril 7.3.Check the surface of homogeneous valve seat and impact head or ring.To assemble1.Lubricate all O-rings by food grade grease before assemble all products.2.To put handle 8 into valve 4 by rotating clockwise.3.Put impact head into valve, then put impact ring, at last put valve seat intovalve.4.Put wetting gasket 2 attached to the surface of valve seat.5.Check out if there is gasket in the hole of the first-stage valve, then put itinto valve body and fix the bolts.6.To assemble the second-stage valve is the same progress as the first-stage.4.4 To disassemble and assemble the pressure blockTo disassemble1.Remove the fixed bolt 1 by spanner of 24#2.Hold pressure block 2 to pull it out gently, then remove pressure block. Theweight of pressure block is 20KG.3.Remove oriented ring 4 and support block 6 in turn. Do not touch plunger.4.Check out if the ceramic plunger is loosed.To assemble1.To assemble support block 6, vent side down. Mounted on four bolts.2.Set oriented ring 4 into plunger. Put them into support block.3.Ceramic plunger and plunger seal are wetted by water. It is good forlubrication.4.Push pressure block 2 gently until it contact with support block 6.5.Lock fixed bolts tightly.ATS ENG INC.215 Common errors and solutionsCondition Reason SolutionMotor is not working No powerCheck electrical connectionMotor is working but nothing out fromoutlet Air plug in pressure block so material can not flow Plunger is rupture Open inlet valve to discharge air Change another plunger No pressureInlet valve seat is wear outPressure gauge is damagedChange another valve seator pressure gauge Unstable pressureGauge is damagedImpurity is in material Air is in materialChange another gauge Pretreatment again Discharge airNo material out orreduction afterincreased pressureInlet valve or valve seat iswear outCheck out and change a newoneNo display on gaugePressure gauge is damagedor no powerChange gauge or battery。
