KAM® HOMOGENIZER

TEL +1 713 784-0000 FAX +1 713 784-0001 Email Sales@Kam.com

KAM CONTROLS, INC.

3939 Ann Arbor Drive Houston, Texas 77063 USA

www.KAM.com

User ManualHOMOGMANUAL-0914

An ISO 9001 certified company

KAM CONTROLS, INC.1HOMOGMANUAL 0914

TA B L E O F C O N T E N T S

SECTION TITLE PAGE 1 Warranty 2

2 Introduction 3 •AvailableModelsandOptions 3 •TheoryofOperation 4 •Specifications 4

3 Assembly and Operations 5 •StandandDriveUnitAssembly 5 •ConnectingtheGeneratortotheDriveUnit 6 •RunningtheGeneratorWithinaContainer 7 4 Maintenance 8 •Cleaning 8 •DismantlingtheGenerator 8 •18mmx200mmGeneratorAssembly 9 •25mmx200mmGeneratorAssembly 10 •ReassemblyoftheGenerator 11 •DriveUnitMaintenance 11

KAMCONTROLS,INC.reservestherighttomakechangestothisdocumentwithoutnotice.

KAM CONTROLS, INC.2HOMOGMANUAL 0914

WA R R A N T Y

WHAT IS COVERED

KAMCONTROLS,INC.warrantsthattheinstrumentwillbefreefromanydefectinpartsorworkmanshipandwill,atitsoption,replaceorrepairanydefectivepart(excludingconsumables)orinstrument.

FOR HOW LONG

Thiswarrantyremainsineffectfor1yearfromthedateofdeliverytotheoriginalpurchaser.

WHAT IS NOT COVERED

Thiswarrantywillbenullandvoidiftheuserfailstofollowallinstructionsontheinstrument,intheOperatorsManual,andinthesoftware,including,butnotlimitedto:•timelyreplacementofconsumables•adherencetorecommendedoperatingprocedures

Thiswarrantydoesnotcoverconsumables(asdefinedinOperatorsManual)orpartorworkmanshipwhichhavebeendamageddueto:•Neglect,abuse,ormisuse•Damagecausedbyortotestsamples•Damageincurredduringinstrumentrelocation•Damagecausedbyortoanyattachedequipment•Useofincorrectlinevoltageorfuses•Improperorunauthorizedrepair,or•Anyotherdamagecausedbypurchasesoritsagents,and•Fire,flood,"actsofGod"orothercontingenciesbeyondthecontrolofKAMCONTROLS,INC.

RESPONSIBILITIES OF PURCHASER

Toensurewarrantycoverage,purchasermust:•Returnthewarrantyregistrationcard•Usetheinstrumentaccordingtodirections(seeOperatorsManual)•Connecttheinstrumentproperlytoapowersupplyofpropervoltage•Replaceblownfuses•PerformroutinemaintenanceasspecifiedintheOperatorsManual

HOW TO GET SERVICE

PurchasershouldcontacttheServiceDepartmentofKAMCONTROLS,INC.forwarrantyserviceinformationandforpropercartingandshippinginstructions.AreturnauthorizationnumbermustbeissuedpriortoreturningshipmentstoKAMCONTROLS,INC.forrepairorotherwise.

WARRANTY DISCLAIMER

KAMCONTROLS,INC.herebyexcludesanddisclaimsanywarrantyofmerchantliabilityorfitnessforanyparticularpurpose.Nowarranty,expressorimplied,extendsbeyondthefacehereof.KAMCONTROLS,INC.shallnotbeliableforlossofuseofinstrumentorotherincidentalorconsequentialcosts,expensesordamagesincurredbythepurchaseroranyotheruser.

PURCHASER'S RIGHTS UNDER STATE LAW (U.S. ONLY)

Thiswarrantygivesthepurchasesspecificlegalrights,andthepurchasermayalsohaveotherrightswhichvarystatetostateintheUnitedStates.

KAM CONTROLS, INC.3HOMOGMANUAL 0914

I N T R O D U C T I O N

AVAILABLE MODELS and OPTIONS

KAMHomogenizerpartsaresoldseparately.

HomogenizerDriveUnit(part#KAM09014)

DispersingTool/Generator

Availableinthreesizes:

10mmdiameterfor10to50mlVolume(KAM09012)20mmdiameterfor50mlVolume(KAM09019)30mmdiameterforlargercontainers(KAM09009)

24"LaboratoryStand(KAM09018)

KAM CONTROLS, INC.4HOMOGMANUAL 0914

I N T R O D U C T I O N C O N T I N U E D

THEORY OF OPERATION

TheKAMHomogenizerisdesignedtodisperseandemulsifyorganicandinorganicmaterialsinaliquid/liquid,liquid/solid,orsolid/solidstate.Ithasthenecessarytorquetoprocessdifficultsamples,andbecauseit'slightweight,itcanbeusedinamountedpositionforhands-freehomogenizationand/orasahandheldhomogenizer.

Duringoperation,themediumtobeprocessedispulledintothebottomofthetubebytherotorandforcedoutthesidesthroughthestatorslots.Thestatoractsfirstofallasanidealflowbreakerandprevents,toalargeextent,therotationofthemedium,allowingtheintroductionoflargemechanicalenergiesinaverysmallspace.Thevortexformationcommoninstirringisgreatlyreducedbutcannotbeavoidedaltogether.Intheshearinggapbetweentherotorandstator,approximately1000timesmoreenergyisintroducedintothemediumthatwouldbewithstirring.Theparticlesarepulledintothecenteroftherotorandthenforcedradiallyoutward.Inthisprocesstheparticles,byhittingsharpedgesandbycavitation,arereducedinsize.Itusuallytakesonlyafewminutestoobtainafineparticlesizereduction.Longerprocessingtimesachieveonlyaninsignificantimprovementinparticlesizereduction,whileincreas-ingthetemperatureofthemediumthroughtheenergyinput.

SPECIFICATIONS

AngularVelocityRangeinRPM: Variablespeed10,000-30,000rpm

Dimensions(driveunit): Height8.5",Width2.75"(216mmx70mm)

Dimensions(stand): Height24",Width7",Depth8.25"(610mmx178mmx210mm)

Weight(driveunit): 2.1lbs(1.4kg)

Weight(stand): 12lbs(5.4kg)

PowerRequirements: 120Volts,50/60Hertz,4.8Amps

Wattage: 576

NoiseRating: 72dB

KAM CONTROLS, INC.5HOMOGMANUAL 0914

A S S E M B LY a n d O P E R AT I O N S

STAND AND DRIVE UNIT ASSEMBLY

Attachthetwosidelegstothebacklegusingthefour(4)3/8-16x21/4socketheadcapscrewsincluded.

Installthelevelingscrewassemblyintothethreadedholelocatedinthetopoftheleftleg.

Madesurethatthethree(3)rubberfeetarelocatedintheotherthreecornersofthelegs.

Insertthe24"longsupportpost(cordholderendupward)intotheholelocatedatthebackofthebase,andtightenthe3/8hexboltandjamnut.

Openonesideofthepostclampandinsertitontothepostandtighteninplace.

Screwthecross-rodassemblyintothethreadedholelocatedinthebackofthedriveunit.

Oncethecrossrodisthreadedintotherearofthedriveunit,tightenthejamnut,lockingthecrossrodinplace.

Insertthedriveunitwiththecrossrodattachedintothepostclampandtighten.

Withthedriveunitinplaceonthestand,insertthepowercordintotheendcaplocatedintheupperendofthepost.

Oncethestandanddriveunithavebeenassembledandtheelectricalconnectionschecked,thedriveunitmaybetested.Donotuseageneratoratthistime.

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CAUTION:

Runningageneratororchamberassemblywithoutliquidmediacancausedamagetothebearings,unlessthelowerbearingofthegeneratorhasbeenreplacedwithasealedandshieldedstainlesssteelbearing.

KAM CONTROLS, INC.6HOMOGMANUAL 0914

A S S E M B LY a n d O P E R AT I O N S C O N T I N U E D

CONNECTING THE GENERATOR TO THE DRIVE UNIT

Thegeneratorisfittedintothedriveunitbyinsertingtheupperendofthegeneratorintothecollarendofthedriveunit.Fig.2-1.

Aligntheslotsinthegeneratorwiththelocatingpinsinthedriveunitcollarbygentlyrotatingthegeneratorasyouinsertitintothecollar.

Oncealigned,pushthegeneratorinwardasfaraspossibleandturnthegeneratorclockwise1/4turn.Thecollarisspringloadedandsomeresistanceisnormal.Fig.2-2

Havingturnedthegeneratorasfarasitwillgo,releasethegenerator.Youshouldhearadistinctclickasthegeneratordropsintoitslockedposition.

Todisconnectthegenerator,pushitupintothedriveunitcollarasfaraspossibleandturnitclockwise1/4turn.

FIG. 2-2FIG. 2-1 Drive unit collar

Generator

¼ Turn

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KAM CONTROLS, INC.7HOMOGMANUAL 0914

A S S E M B LY a n d O P E R AT I O N S C O N T I N U E D

RUNNING THE GENERATOR WITHIN A CONTAINER

Themotorandgeneratormaybeusedaseitherahand-heldunitormountedtothestand.

Ideally,thediameterofthegeneratorisaslargeasthecontainerwillallow.

Insertthegeneratorintothemediumthatistobehomogenized.Thenormalinsertiondepthwouldbe1/2to1/3theheightofthemediummeasuredfromthebottomofthecontainer.Heaviersedimentsmayrequirelowerpositioning,butthegeneratormustnevercomeincontactwiththebottomorsidesofthecontainer.

Startthedriveunitatthelowestpossiblespeedandthenslowlyincreasethespeedtothedesiredlevel.

Ifyouareworkingwithsolid/liquidmixtures,addthesolidmaterialoncethedesiredspeedhasbeenreached.

Ifyouareholdingthemotorunit,itisadvisablethatyouraiseandlowerthegeneratorwithinthemediumasyouareprocessingthesample.Thiswillhelpinspeedingupthehomogenizingprocess.

Ifthemotorismountedtothestand,itisadvisablethatthegeneratorbeimmersedwithinthecontaineroffcenter.Thisoff-centerlocationwillhelpminimizevortexingaswellastheundesirableintroductionofairintoyoursample.

Thegeneratorshavetwo(2)setsofventingholes.Onesetislocatedapproximately1"fromthebottomofthegeneratorandthesecondsetisapproximately1"belowthebottomofthegeneratorcollar.Thelowerholeaidsinkeepingthelowerbearinglubricated,whilethetopholeallowsventingofanyliquidthatmightbeforcedupintothetube.Thereisnoneedtoavoidliquidfromenteringthelowersetofholes.

Onceyouhavereachedtherequiredlevelofprocessing,starttoslowlyremovethegeneratorfromthecontainerwhilethemotorisstillrunning.Itisimportantthatthisbedoneslowlyasyouwanttospinallthemediumfromthegeneratorbackintothecontainerandnotoutsideofthecontainer.

Afterspinningthemediumoffthegenerator,themotorcanbeturnedoffandthegeneratortotallyremovedfromthecontainer.

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WARNING:

Neverattempttoholdthelowerendofthegeneratorwhilethegeneratorisattachedtothemotor.

KAM CONTROLS, INC.8HOMOGMANUAL 0914

M A I N T E N A N C E

CLEANING

DISMANTLING THE GENERATOR FOR CLEANING AND REPAIR

Immediatelyafterfinishingworkwiththeapparatus,thegeneratormustbecleanedsothatsubstanceresiduescannotsticktotherotorandstatorandallowsmallbacterialculturestoforminundesirableplaces.Forthispurpose,thegeneratorshouldberuninasolventwhichdissolvesanyresidueanddoesnotharmthegeneratorcomponents.Therotorandstatorarecleanedasthesolventispumpedthroughthegenerator.

Thegeneratorcanbesterilizedbyanyoneof4processes:

A.Germicidalsolutions(formalin,phenol,alcohol,etc.)candisinfectinmostcases.However,any germicideresiduemustsubsequentlyberemovedwithsterilizedwater.

B.Steamatapressureof2baraboveatmosphericandatemperatureof120°C.

C.Hotairatatemperatureof160°to190°C.

D.Flaming.However,itisonlyaffectiveonexternalsurfaces.

Removetherotorshaftcollarassembly(1)fromtheendofthegeneratorbylooseningthesetscrewlocatedinthesideoftherotorshaftcollarusingthe5/64hexwrenchsuppliedinthetoolkit.

Removethenylonwasher(3)fromthetopofthegeneratorassembly.

Withtherotorshaftcollarassembly(1)andthenylonwasher(3)removed,slidetherotorshaft(2),therotorknife(8),andthelowerbearing(7),asanassembly,offthelowerendofthegenerator.

Toremovetherotorknife(8)andthelowerbearing(7),attachtherotorshaftcollar(1)totheupperendoftherotorshaft(2).Withtherotorshaftcollarattached,insertthe1/4"hexwrenchintotheendoftherotorshaftcollarandwiththescrewdriverinsertedthroughtherotorknife,turnthehexwrenchcounterclockwise.Thiswillremovetherotorknifefromtherotorshaftandallowthelowerbearingtoberemoved.Thelowerbearingshouldbereplacedbeforethebladeisallowedtocomeincontactwiththeinsidewallofthegeneratortube.

Toclean,rinsethegeneratorinacleaningmaterialorsolvent.ThesolventmustnotattackstainlesssteelorPTFE.Forathoroughcleaning,thegeneratormustbedismantled,asthemediumalsowetstheinnerwallofthetube.

Aftercleaning,sterilizationmethodsA,B,orCaresuitableforsterilizingthegenerator.

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SeeFIGS.3-1,3-2

KAM CONTROLS, INC.9HOMOGMANUAL 0914

Rotorshaftcollarassembly(1)

Rotorshaft(2)

Nylonwasher(3)

Upperbearing(4)

Midbearing(5)Tubeandcollarassembly(6)

Rotorknife(8)

Lowerbearing(7)

M A I N T E N A N C E C O N T I N U E D

FIG. 3-118MMX200MMGENERATOR

KAM CONTROLS, INC.10HOMOGMANUAL 0914

Rotorshaftcollarassembly(1)

Rotorshaft(2)

Nylonwasher(3)

Upperbearing(4)

Midbearing(5)

Tubeandcollarassembly(6)

Rotorhead/stator(7)

Lowerbearing(8)

Rotorknife(9)

M A I N T E N A N C E C O N T I N U E D

FIG. 3-2 25MMX200MMGENERATOR

KAM CONTROLS, INC.11HOMOGMANUAL 0914

M A I N T E N A N C E C O N T I N U E D

Slidethelowerbearing(7)ontotheendoftherotorshaft(2),andthenscrewtherotorknife(8)ontotheendoftheshaftandfingertighten.

CAUTION:overtighteningoftherotorknifeontotherotorshaftcanresultintheshaftbreakingand/ordistortionoftherotorknife.

Inserttheupperbearing(4)intothetopofthetubeandcollarassembly(6).Thebearingisproperlypositionedwhentheflangeofthebearingisflushagainstthetopofthetubeandcollarassembly.

InserttheassemblyfromStep1intothebottomendofthetubeandcollarassemblyandpushitupwarduntilpassesthroughtheupperbearing.

Oncetheshaftassemblyhasbeeninsertedintothetubeandcollarassembly,placethenylonwasher(3)ontheendoftheshaftwhichisextendingthroughtheupperbearing.

Standthegeneratorassemblyonaflatsurfacewiththebladeenddownward.Pushtherotorshaftcollarassembly(1)downwardontotheendoftheshaftuntilthenylonwashisincontactwithboththebottomoftherotorshaftcollarassemblyandthetopoftheupperbearing.Tightenthesetscrewlocatedinthesideoftherotorshaftcollarassemblyandcheckthatthegeneratorrotatesfreely.

REASSEMBLYOFTHEGENERATOR

DRIVEUNITMAINTENANCE

Thebrushesshouldbeinspectedfrequentlywhentheunitisusedcontinuously.Ifyourmotorunitrunssporadically,losespower,makesunusualnoisesorrunsatareducedspeed,checkthebrushes.

WARNING:Tocontinueusingthedriveunitinthisconditionwillpermanentlydamagethemotor.

Tocheckthebrushes,withthecordunplugged,removedthedriveunittopcapandcheckbothbrushesoneatatime.Ifthebrushislessthan1/8"longortheendsurfaceofthebrushthatcontactsthecommutatorisroughand/orpitted,itshouldbereplaced.Usuallythebrusheswillnotwearoutsimultaneously.However,ifonebrushisworn,replacebothbrushes.Makesurethatthebrushesareinstalledproperly.Thecurvedsurfaceofthebrushmustmatchthecurvatureofthecommutator.Afterreplacingthebrushes,themotorshouldberunatno-load.Placethedriveunitonacleansurfaceandrunitfreelyfor5minutesatapproximatelyhalfspeed.Thiswillallowthebrushestoseatproperlyandwillincreasethelifetimeofeachsetofbrushes.Thiswillalsoextendthetotallifeofthemotorsincethecommutatorsurfacewillwearlonger.

WARNING:

TheKAMHomogenizerdriveunitissuppliedwithsealedballbearingsandrequiresnoadditionallubrication.

Anyserviceofthedriveunitotherthanbrushreplacementshouldbeperformedbyanauthorizedservicerepresentative.

UseofanyaccessoriesorattachmentsotherthanthosesuppliedbyKAMCONTROLSmaybehazardous.

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