Operating Instructions for the Disk Mill Model DM200
Contents
1. Operating Instructions for the Disk Mill Model DM200 Jetsch Retsch GmbH 42781 Haan Rheinische Str 36 Germany Doc Nr GB 98 740 9999 16 11 2006 Retsch GmbH Information on these Operating Instructions The present operating instructions for the laboratory model DM200 disk mill provides you with all of the necessary information on the areas specified in the table of contents It is an instruction for the target group s defined for each of these areas in the safe and intended use of the DM200 The prerequisite of each of the target group s being able to use it safely and as intended is having a knowledge of the relevant sections The present technical documentation is a reference work and instructions for learning and each of the sections is closed in and of itself These operating instructions are not instructions for repair If repairs should be necessary please consult your vendor or get in contact with Retsch GmbH di rectly 2 Doc Nt GB 98 740 9999 16 11 2006 Retsch GmbH SAlCCY icine senuassceeswats ccuvwass EE 4 Safety INFOrmation ccccceccesssseeeccuceeeuuuueeeennnees 4 Warning SIONS xadscontessteonidesaeeticas E 4 RC Pell S batt EEEE EEEE EE 5 CONTPIMALION airia E vane 5 TECHNICal Data iiciscesiccdiwesiecviecsiensieesteetieerecevnreres 6 Use aS intended cccccccceceuuuueeeeeneeeeeeuuueeeunneees 6 FUNCHONal DESCHDUON srini an 6 Protective EQUIPMENT ciranean en 7 DPV O aTa Oi 72. Doc Nr GB 98 740 9999 16 11 2006 Resch GmbH A General Information Accessories Cleaning You may pull out the collecting container for cleaning pur poses Open the door to clean the milling discs the milling space and the funnel tube You may now conveniently clean the entire area that has come into contact with the material to be crushed with the aid of a brush or vacuum cleaner Do not clean the DM200 with flowing water Danger from Current Surge Only use moistened rags Solvents are not permitted The protection type of DM200 is IP 55 Service The DM200 does not require service although it e _ __ _ should be relubricated on the lubricating nipple of the shifting sled Conventional lubricating grease may be used for this purpose A grease gun is also available as an accessory under the order no 05 185 0006 Necessary Safety Tests The safety limit switches on the door and the collecting container should be checked on a monthly basis to see if they are in perfect working order e open the door It may not be possible to switch on the DM200 any more with the ON OFF switch e close the door It must be possible to start the DM200 with the ON OFF switch again e pull out the collecting container It may not be possible to switch on the DM200 any more with the ON OFF switch e push in the collecting container It must be possible to start the DM200 with the ON OFF switch a
3. purpose planned by the customer The shall apply to the performance data that the customer expects unless we have been able to make appropriate practical laboratory ex periments ahead of time and declared the corresponding performance data to be binding in our order confirmation in writing Our warranty shall also be invalid if persons other than those commissioned by us do repairs or otherwise interfere with or modify the goods supplied by us or do not use the suitable accesso ries to the extent that the deficiency occurring is in causal connection with that Otherwise the prerequisite for our warranty shall be complying with our operating instructions and instruc tions for use If the customer builds the goods in other systems or production plants or connects them up to them or interlinks or processes them without our prior approval our warranty shall be exclu sively limited to the components supplied by us We may either remedy defects or exchange defective components at our choice at the place of installation of the object of sale or in our company If the defect is remedied at the place of in Stallation the customer has to grant our representative temporally and spatially unobstructed access to the object of sale Otherwise the customer may only demand that the warranty work only be done during the business hours normal at the location Should the warranty work be done outside of our normal business hours at the request of the purchaser
4. the Warranty sssssssccecececceceeennnnes 19 3 Doc Nr GB 98 740 9999 Safety The DM200 laboratory disk mill is a highly modern high performance product from Retsch GmbH and is State of the art If the machine is used as intended and if the user has a knowledge of the technical documentation here it is completely safe when oper ated Safety Information You as the operator have to ensure that the persons entrusted with working at the DM200 have taken notice of and understood all of the regulations in the area of safety know all of the instructions for use and regula tions of the target group relevant for them be fore commencing work e have access to the technical documentation of this machine at any time and without any problems Before work is commenced on the DM200 ensure that new personnel has been made familiar with its safe and intended use either by having a competent person introduce it to them orally and or based upon the present technical documentation Improper operation may lead to personal injury property damage or injury You are responsible for your own safety and that of your employees Ensure that no unauthorised persons have access to the DM200 laboratory disk mill For your own protection have your employees con firm that they have been instructed in the operation of the DM200 You will find the draft of the appropri ate form after the section on safety We will not be liable fo
5. the customer has to bear the additional costs If he wishes other special services going beyond the warranty work these expenses shall be paid at the prices of us valid at the time 16 11 2006 Retsch GmbH 19 Doc Nr GB 98 740 9999
6. 1 2006 Retsch GmbH Emissions Characteristic Noise Values Noise measurement in conformity with DIN 45635 031 01 KL3 The properties of the material to be crushed also has an effect upon the characteristic noise values sound level Lwa 81 dB A emission read at the workpiece Lpaeq 69 4 dB A Machine Dimensions height 400 mm 500 mm with the vertical flap on the funnel width 430 mm 900 mm with door opened at 180 depth 890 mm 1 000 mm with door opened at 90 weight approximately 140 kg Floor Space Required 430 mm x 1000 mm a safety distance is not necessary 8 Doc Nt GB 98 740 9999 Transportation and Installation Packaging Packaging is in accordance with the transportation path and satisfies the generally recognised packaging guidelines Please store the packaging for the duration of the V warranty period because your warranty claim would be endangered if there were a complaint and it were returned in insufficient packaging Transportation In order to be able to transport the DM200 in a crane of a minimum load bearing capacity of 250 kp it should be hoisted with the hoisting equip ment as shown in the adjacent figure The DM200 may not be shocked shaken or V thrown during transportation Otherwise the electronic and mechanical component parts could be damaged Temperature Fluctuations If there are strong temperature fluctuations for instance when being transp
7. MOCOF OUUDUU csik aranna EEA OES 7 Rated Voltage S maura es cioiat ena aki 7 ROI S ae E enema mamemenmennnmees 7 Protective TYPES suds ene E E 7 aA EO AEE TT E T ATE PA T E A 8 Machine DimMmenSioOnS sssesssssssessrssnsnnsnsrrsnsrnenns 8 Floor Space Reguired areire aii 8 Transportation and Installation ccccccceeeennnnnes 9 PACKAGING wer cvannctincrndvaidianbed Seana eadedantedddauneeadtaans 9 TRAN SDOFLAUION sicteanscsastevicnistavicucisestcasstaniceesiaeis 9 Intermediate Storage ccccccccccccccccccccccceceeeeeeecs 9 SCOPE of DElIVEFY siisii tev shucee sate weeks 9 The Parameters for the Place of Installation 11 Metala H Oare 11 Electrical CONNECTION cccccceeeeeeeeeueeeeecceeeeunnees 11 ODCAEION siisii EENAA 12 The Operating Elements and Operation asees 12 Adjusting the Gap Width cccccceeeeeeeseeeeeeeees 13 Starting the Machine sessssesssssrsensrrsnsrnsnsnssrene 13 Feeding the Material to be CrusShed cccceees 13 Changing the direction of rotation replacing the milling GISKS tecccduauevessuicdvcidtedmwnieusvarcieuavewets 14 General Information cccccccccccceeennnnnnneeeeeeeeseneees 16 ACCE SOTE ect iieten a cyenaaa mans E 16 CHE QNIMNG soiree EEE 16 DOIVICC SuTree CNi 16 Necessary Safety TeSUS cccccceeeeeesseeeeeeeeeeeenees 16 CODY FIGH Caactaunwetanieas a N AEA 16 MOGITICATIONS sosojos ENAS 16 Safety Regulations Table cccccceeeeeeeeeeeeeees 18 The Terms of
8. e hexagon bolts or hexagon nuts with an open jawed spanner e Open the door e Keep a firm hold on the milling disk while unscrewing both hexagon bolts with washers e Remove the milling disk e Clean the mounting of the milling disk in the door e Insert a new milling disk so that its contact surface is level e Screw in the hexagon bolts again for zirconium oxide hexagon nuts are used 16 11 2006 CO Resch Gobi 14 Doc Nr GB 98 740 9999 Replacing the milling disk in the housing e Disconnect the mains plug e Remove the collecting vessel e Open the door e Lift up the cover e Unscrew the hexagon bolts or hexagon nuts with an SW 30 open jawed spanner e Remove the milling disk e Clean the mounting of the milling disk e Place a new milling disk in position e The milling disk must have a level contact surface e Screw in the hexagon bolts with washers for zirco nium oxide hexagon nuts are used Caution It is essential that the milling disks have a level contact Surface There should be no unevenness or other components under the milling disk For zirconium oxide disks it is absolutely necessary that the rubber washer GS is placed under the steel washer SS Caution Milling disks of zirconium oxide should be tightened with a torque of only 20 30 Nm Do not forget the rubber washer GS Milling disks of steel and tungsten carbide are tightened with a torque of 50 100 Nm 16 11 2006 Retsch GmbH 15
9. gain If the machine is not functioning properly do not con tinue to operate it and get in contact with our cus tomer service Copyright It is only allowed to pass on or copy this documenta tion or utilise and pass on its content with the express permission of Retsch GmbH Non compliance engages the obligation of compensa tion for damage Modifications 16 Doc Nr GB 98 740 9999 We reserve the right to make technical modifications 16 11 2006 Retsch GmbH 17 Doc Nr GB 98 740 9999 property damage and personal injury may be incurred if the safety information is not observed intended use do not mill any explosive self danger to life and limb because of igniting or fire promoting materials explosion because the DM200 is not Posi designed to be explosion protected no claims to compensation for dam age shall be accepted whatsoever safety information do not mill materials whose fine danger to life and limb because of proportion at a certain percentage explosion because the DM200 is not may lead to an explosion designed to be explosion protected do not modify the machine and otherwise the conformity with Euro only use the spare parts and ac pean directives declared by Retsch cessories approved by Retsch shall be rendered invalid Furthermore this leads to the loss of all warranty claims please store the packaging for the if there is a complaint and i
10. ified This shall also apply with reference to the costs of shipping and the appropriate costs of removing and installing However the customer shall bear the appropriate costs for providing his own installers and help on site To the extent that our customer works abroad we shall be entitled as a deviation from this to pay the costs necessary for remedying the defect especially transportation travel ling and material costs from the German border The warranty term for newly manufactured goods is two years for used it is one year The guarantee refers to deployment in a laboratory in 1 shift operation In case of multi shift operation or other areas of application the guarantee term is shortened accordingly No warranty is given for parts subject to wear and tear We shall assume the warranty for our goods being free of manufacturing deficiencies The Suitability classification and functioning of our goods shall be exclusively determined according to the performance specifications in the order confirmation even if this deviates from the or der In this case the customer has the possibility of pointing out any differences to the order within two weeks after receiving our order confirmation and reaching an agreement with us on this If he does not object to the specifications in the order confirmation it shall be deemed as accepted In the absence of a deviating agreement we shall not be liable for the article of sale being Suited to the
11. nce data in an unpredictable fash ion Installation Altitude a maximum of 2 000 m above sea level Installation Only place the DM200 on a solid and sturdy founda tion Electrical Connection The mains fusing should be designed as follows at 3 230 and 3 N 400V 16A at 3 115 and 3 200V 20A e you may find the voltage and frequency of the DM200 on the nameplate please ensure that the values agree with the ex isting power mains only connect the DM200 to the power mains with the aid of the cable connector supplied You may have the connection made directly with a change over switch to avoid having to call in an elec trician This has the benefit that the milling disc teeth may be used by both sides This is described in the section Changing the Direction of Rotation and Replacing the Milling Disc Electrical and mechanical component parts may be damaged if the values on the nameplate are not complied with Modifications or rebuilding it to a supply voltage other than stated on the machine nameplate should only be done by an electrician Danger of Current Surge 11 Doc Nr GB 98 740 9999 Operation The Operating Elements and Operation element function door seals the milling space dustproof funnel tube window milling gap receives the material to be milled enables you to check the milling gap by means of blade gauge collecting container receives the crushed ma
12. nent parts cleaning do not clean the DM200 with flow danger from current surge ing water the protection type of the DM200 is IP55 get in contact with customer ser if defects are improperly repaired this vice if the safety equipment func may lead to danger to life and limb tions improperly 16 11 2006 Retsch GmbH 18 Doc Nr GB 98 740 9999 The Terms of the Warranty We will remedy defects or furnish replacement at no charge if complaints are justified The purchaser shall only be entitled to repudiation of contract or diminution if according to our decision it is not possible to remedy the defect or replacement cannot be made or the period for this cannot be maintained or it was our fault that an appropriate subsequent period set by the customer of at least six weeks was not maintained If the remedy or supplying the replacement is finally unsuccessful the customer may demand that the remuneration be reduced or withdraw from the contract at his choice Further claims especially to compensation for damage that were not incurred on the object itself such as a loss of production shall be excluded to the extent that we are not guilty of intent or negli gence We pass on the manufacturer s liability for external products We shall bear the immediate costs incurred by remedying the defect or supplying a replace ment under the proviso that the complaint has turned out to be just
13. orted by aeroplane the DM200 should be protected from condensa tion water Otherwise there could be damage to the electronic component parts lt Intermediate Storage Please also ensure that the DM200 is stored dry if it is placed in intermediate storage Scope of Delivery e the DM200 disk mill e the operating instructions Please check to see whether the delivery is complete including the accessories specifically ordered Check to see whether the DM200 is in perfect work ing order refer to the section on operation for this If the delivery is incomplete and or if there was damage during transportation you have to notify the transporter and Retsch GmbH without delay within 24h Under certain circumstances later complaints may not be recognised 16 11 2006 Retsch GmbH 9 Doc Nr GB 98 740 9999 16 11 2006 ORs Case 10 Doc Nr GB 98 740 9999 16 11 2006 Retsch GmbH V V The Parameters for the Place of Installation ambient temperature 5 C to 40 C If the temperature is above or below the ambient temperature the electronic and mechanical compo nent parts may be damaged changing the perform ance data in an unpredictable fashion humidity The maximum relative humidity is 80 at tempera tures up to and including 31 C decreasing linearly to 50 relative humidity at 40 C If the humidity is higher the electronic and me chanical component parts may be damaged chang ing the performa
14. ote the de creasing intensity of the milling sound to ascertain the optimum feed quantity 16 11 2006 Retsch GmbH 13 Doc Nr GB 98 740 9999 Caution Only feed the material to be crushed after having started the DM200 If the DM200 starts up filled with material to be crushed this may lead to damage in the mechanical component parts Changing the direction of rotation re placing the milling disks The milling disks are subject to natural wear after use over a long period However before they need to be replaced by new ones the direction of rotation of the motor can be changed so that the opposite side of the gear teeth can be used By this means the service life of the milling disks can be extended Changing the direction of rotation By reversing the phases of the mains supply the direction of rotation of the motor can be changed Since this neces sitates intervention in the electrical connecting line of the DM200 the change in direction of rotation should be car ried out only by a qualified electrician However it is possible to install a direction of rotation change over switch when connecting up to the mains sup ply for the first time It is then no longer necessary for an electrician to intervene when the the direction of rotation has to be changed again Replacing the milling disk in the door e Disconnect the mains plug e Remove the collecting vessel e Keep the door closed e Slightly unscrew th
15. per sons from unintentionally putting their hands in the ma chine when it is running funnel tube designed in conformity with EN 294 This prevents persons from putting their hands into the milling space when the flap is opened safety limit switch This prevents the machine from starting up when the milling space is open It also stops the motor within a safe period of time when the milling space is opened during operation safety limit switch This prevents the machine from starting up when the collecting container is drawn out It also stops the motor within a safe period of time when drawing out the collecting container protective motor switch ON OFF switch This switches off the machine automatically if there is a defect or if the motor is overloaded position I the machine starts position O the machine stops This prevents the machine from starting up inde pendently if there is an electrical defect or power failure Drive standard three phase gear motor Motor Output 1 500 Watt Rated Voltages 3 230 V 50 approx 5 7 A 60Hz 3 N 400V 50 approx 3 3 A 60Hz 3 115 V 50 approx 11 4 60Hz A 3 200 V 50 approx 6 5A 60Hz Rpm s 50Hz Rpm s 440 min 60Hz Rpm s 528 min Protective Types gear motor IP 55 Safety limit switch for the door IP 67 safety limit switch for the collecting IP 67 container protective motor switch ON OFF IP 55 switch 7 Doc Nt GB 98 740 9999 16 1
16. r any claims to compensation whatsoever for property damage or personal injury that were caused by not observing the following safety information Warning Signs we give warnings with the following signs personal injury V property damage 16 11 2006 Retsch GmbH 4 Doc Nr GB 98 740 9999 16 11 2006 Retsch GmbH Repairs These operating instructions are not instructions for repair For your own Safety repairs may only be done by Retsch GmbH or an authorised agency or service technicians i aaee ar ee _retsch GmbH directly Confirmation I have taken notice of the foreword and the section on safety the signature of the operators the signature of the service technician 5 Doc Nt GB 98 740 9999 16 11 2006 Resch Grb lt Technical Data machine model designation DM200 Use as intended The DM200 laboratory disk mill is suited for finely milling soft to hard materials up to 8 Mohs in sets or continuously from the fields of mining and metal lurgy rocks and earth the glass industry or soil re search Our applications laboratory would be glad to give you further information upon request The DM200 is designed for quantities from 20 to ap proximately 150 Kg h depending upon the setting of the discharge gap and the piled density and crushing behaviour of the sample The feed size may not ex ceed an edge length of a maximum of 20 mm The DM200 i
17. s not designed to be explosion pro tected and therefore it is not suited to milling explosive self igniting or fire promoting sub stances If oxidised materials are milled such as metals organic materials wood plastics etc there is the danger of self ignition dust explosion if the proportion of fines exceeds a certain percentage It is necessary to observe the appropriate safety guidelines when materials such as these are crushed Do not modify the machine and only use the Spare parts and accessories approved by Retsch Otherwise the conformity with European di rectives declared by Retsch shall be ren dered invalid Furthermore this leads to a loss of all war ranty claims Functional Description The material sample is crushed by two milling discs coarsely meshed on the inside working against one another in a milling space sealed against dust from the outside One of these is driven by a powerful and slow moving gear mo tor The material to be milled is filled into the centre of the stationary milling disc through a closable funnel and it escapes from the gap between the two disks after being crushed by compressing and shearing force The width of the gap can be adjusted and controlled from outside and deter mines the mean granulation of the material to be milled 6 Doc Nr GB 98 740 9999 16 11 2006 Resch Grb Protective Equipment The following safety equipment reliably prevents
18. st the gap width when the machine is running Material that is difficult to mill should be milled at least twice Select a larger gap width as pre crushing for the first pass and then you achieve the desired final fineness with the small gap in the second milling pass Caution The smallest gap width is 0 1 mm The milling discs may not touch one another because other wise this could damage the milling discs Starting the Machine It is only possible to start the DM200 when the door is closed and the collecting container has been inserted The ON OFF switch is on the right hand side of the DM200 e ON OFF switch position I DM200 starts position 0 DM200 stops The ON OFF switch also acts as a protective motor switch If the motor is overloaded or if there is another electri cal fault this switch disconnects the DM200 from the mains The DM200 can only start up when the DM200 is manually started with the ON OFF switch Feeding the Material to be Crushed After the gap has been set and the DM200 has been started you commence material feed Do not exceed a maximum edge length 20 mm Open the lid of the fun nel tube for this purpose e the lid of the funnel tube When feeding the material to be crushed please ensure that the funnel tube lid is closed because otherwise the material to be crushed could fall back Furthermore the quantity of fed material to be crushed depends upon its millability Therefore n
19. t is re warranty period turned in insufficient packaging this may jeopardise your warranty claims electronic component parts may be temperature fluctua protect the DM200 from conden tions sate water forming if there are damaged I temperature fluctuations transportation ES not shock shake or throw the electronic and mechanical component DM200 during transportation parts may be damaged scope of delivery if the delivery is incomplete and under certain circumstances later or if there is damage from trans complaints may not be recognised portation you have to inform the transporter and Retsch GmbH without delay within 24h should not fall below 5 C electronic and mechanical component Should not go above 40 C parts may be damaged and perform ance data may change unpredictably humidity do not exceed a relative humidity higher humidity may damage the of 80 at 31 C or 50 descend electronic and mechanical component ing linearly at 40 C parts and performance data may electronic and mechanical component adjusting the gap do not adjust a gap width lt 0 1 if the milling discs come into contact width mm Hee another they may be dam aged feeding the material only feed material to be crushed if the DM200 starts up filled with to be crushed when the DM200 is operating material to be crushed this may dam i age the mechanical compo
20. terial to be milled milling disc doors crushes the material to be milled fed into it together with F milling disc housing crushes the material to be milled fed into it together with E safety switch for the door prevents the machine from starting up when the door is open lubrication point enables you to relubricate the coupling door lock enables you to open and safely close the doors protective motor switch position I the machine is switched on position 0 the machine is stopped item A B C D E F G H I J K gap adjustment crank enables you to adjust the gap together with C graduation line 0 01 mm 16 11 2006 safety switch for the col _lecting container Retsch GmbH prevents the machine from starting up when the collecting disconnect the motor from the mains if there is an overload container is drawn out 12 Doc Nr GB 98 740 9999 Adjusting the Gap Width You may adjust the gap width between the milling disc in the housing and in the door just by adjusting the gradu ated rotating crank mounted below the motor 1 gradua tion line 0 01 mm You may adjust the gap from 0 1 to approximately 5 mm e Rotating Crank Caution Do not go below the minimum gap width of 0 1 mm You may control check the gap width setting through a window behind the funnel tube by means of a sensing gauge e Window You may also adju
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