Operating Manual DM400 Disc Mill Original © Retsch GmbH, 42781 Haan, Retsch-Allee 1-5, Germany 18.07.
Copyright © Copyright by Retsch GmbH Haan, Retsch-Allee 1-5 D-42781 Haan Federal Republic of Germany
Table of contents 1 Basic construction .................................................................................................................................. 7 2 Safety instructions and use ................................................................................................................... 9 2.1 Requirements for the user ................................................................................................................ 9 2.2 Intended use ...........................
Table of Contents 7 Servicing .................................................................................................................................................41 7.1 Grinding discs .................................................................................................................................42 7.2 Replacing the grinding discs (5 + 6)................................................................................................42 7.3 Replacing the gear oil ................
Table of contents 6
Basic construction 1 Basic construction 4 6 1 11 5 2 8 14 3 10 9 12 7 13 1 Display 2 Control panel 3 Main switch 4 Fill hopper 5 Fixed grinding disc 6 Moving grinding disc 7 Gap set screw 8 Grinding chamber closing mechanism 9 Locking bolts sample material container 10 Sample material container 11 Suction flange lid 12 Height adjustable support 13 Interlock switch 14 Housing cover 7
Basic construction a c b d e f g h i 8 a + button (change parameters and gap width, menu navigation) b - button (change parameters and gap width, menu navigation) c Arrow up button (menu navigation) d Arrow down button (menu navigation) e Start button f Stop button g Button dust extraction (on/off) h Unlocking and locking the grinding chamber i Sensor grinding chamber
Safety instructions and use 2 Safety instructions and use 2.1 Requirements for the user This Operating Manual is intended for persons commissioned with the operation and monitoring of the DM400. The Operating Manual, and in particular the safety instructions, should be heeded by all persons working on or with the equipment. Furthermore the regulations and provisions on accident prevention applicable at the application site must be observed. The Operating Manual must always be kept where the DM400 is used.
Safety instructions and use 2.2 Intended use The DM400 is a disc mill for batch or continuous fine grinding of hard brittle to medium hard solids from the areas of mining and metallurgy, geology and mineralogy and the glass and ceramics industry. The maximum feed size is 20 mm edge length; the achievable final fineness level depending on the gap width set is approx. 12 mm (largest gap width) and 0.05 mm (smallest gap width). The material throughput of the disc mill lies in the range of 20 to 150 kg/h.
Safety instructions and use liability for the functionality of the DM400 or for damage arising from an infringement of this duty. Through use of the DM400 the customer agrees and recognises that defects, faults or errors cannot be entirely ruled out. In order to avoid the risk of personal injury or damage to property arising from this or otherwise or of other indirect or direct damage, customers must take adequate and comprehensive safety measures when working with the device.
Safety instructions and use CAUTION! This combination of symbol and signal word indicates a potentially hazardous situation which can lead to minor or slight injuries if it is not avoided. NOTICE! This combination of symbol and signal word indicates a potentially hazardous situation which can lead to damage to property if it is not avoided. NOTICE! This combination of symbol and signal word indicates a potentially hazardous situation which can lead to damage to the environment if it is not avoided.
Safety instructions and use Special safety instructions The following symbols are used in safety instructions to alert to specific hazards: DANGER! This combination of symbol and signal word indicates a direct hazardous situation through electric current. If a sign with this symbol is not heeded, serious or fatal injuries will result. DANGER! This combination of symbol and signal word designates content and instructions for intended use of the machine in potentially explosive areas.
Safety instructions and use WARNING! This combination of symbol and signal word indicates a direct hazardous situation due to hot surfaces. If a sign with this symbol is not heeded, skin contact with hot surfaces may cause serious burns to skin. Safety instructions in operating instructions Safety instructions may refer to a specific, individual operating instruction.
Safety instructions and use 2.5 Device safety instructions Please note! Only use original accessories and original spare parts. Failure to do so can place the protection of the machine in doubt. Safe conduct must be strictly followed during all work. The current applicable national and international accident prevention regulations must be complied with.
Safety instructions and use CAUTION! Wear hearing protection! Hearing protection should be worn when a noise level of 85dB (A) is reached or exceeded in order to prevent damage to hearing. WARNING! The maximum workplace concentrations (threshold limit values - TLV) in valid safety regulations must be observed, and ventilation must be provided where necessary or the machine operated under an extractor hood. DANGER! Risk of explosion! - When grinding oxidable substances (e.g.
Safety instructions and use 2.6 Safety equipment Safety equipment must be used as intended and must not be rendered unworkable or removed. All safety equipment must be checked regularly for completeness and function. The disc mill has a comprehensive safety system: 1. A grille (4G) prevents contact with the fill hopper (4). 4G 2. A sensor (i) monitors the closing of the grinding chamber before operation and prevents the disc mill starting up after it has been opened. i 3.
Safety instructions and use 4. The interlock switch (13) pulls in the sample material container after the start of grinding and locks it using the locking bolt (9) on the container. During operation the interlock switch monitors whether the device is closed correctly. It likewise prevents the disc mill starting up after it has been opened. The disc mill does not start if the grinding chamber is open or the sample material container is missing. 13 2.
Safety instructions and use 2.8.2 Protection against restarting The device switches off in the event of a power failure during operation.
Safety instructions and use 20
Technical data 3 Technical data 3.1 Dimensions 52 x 105 x 63 cm (width x depth x height) 3.2 Weight 228 kg (net) without griding discs 246 kg with tungsten carbide grinding discs 3.3 Operating noise Workplace related emissions value in accordance with DIN EN ISO 3746:2005 LPA . = 68.9 dB (A) The measurement was conducted with sand as sample material, particle size 0.5 – 2 mm. 3.4 Voltage, power consumption, power input Voltage 400V / 3~ 50Hz 230V / 3~ 60Hz Power consumption 3.2 A 5.
Technical data 3.6 Material Maximum feed size 20mm (depending on the material) Minimum feed quantity 20 - 30ml Batch grinding with collecting container (max. 2l) Maximum throughput 150kg/h with continuous grinding 3.7 Final fineness The final fineness is between 0.05 and 12mm, depending on the sample material.
Installation 4 Installation 4.1 Transport The device is supplied on a transport pallet with wooden cover. We recommend transporting the packaged device with a pallet truck or forklift. DANGER! Do not walk under the transport pallet during transport. WARNING! Incorrect lifting can lead to injury or damage to property.
Installation 4.3 Positioning DANGER! Do not walk under the transport pallet during transport. To position the disc mill you will need a crane or other suitable means of transport as well as 2 carrying straps (not included with delivery) with a minimum length of 40cm and loadbearing capacity of 500 kg. CAUTION! Weight of the disc mill is approx. 260 kg with grinding discs (WC) and transport pallet! NOTICE! The disc mill must be placed on an even, stable surface.
Installation 3. After unscrewing the quick acting screws, pull the housing cover (14) back by a few centimetres. Then lift the housing cover up and out. 4. Two carrying lugs to attach the carrying straps are then visible. 5. Attach the carrying straps to a crane or other auxiliary equipment. 6. Now attach the carrying straps to the 2 carrying lugs provided. 7. With the help of the crane, position the disc mill in the desired place.
Installation - Maximum relative humidity 80% for temperatures up to 31°C, decreasing in a linear fashion to 50% relative humidity at 40°C. The room temperature must be between 5 and 40°C. Height up to 2000m above sea level Degree of pollution 2 in accordance with IEC 664. 4.5 Electrical connection Before connection, compare the voltage and current values on the type plate with the values on the intended mains.
Installation 4.7 Switching on for the first time / function test Only switch the device on when all work described as from the chapter “Installation” has been carried out! 4.7.1 Switching on Set the main switch (3) to I! The display (1) switches on and the STOP button (f) is lit up in red! If the grinding chamber is locked, the release and locking button (h) is lit up in green. 4.7.1.
Installation 28
Working with the disc mill 5 Working with the disc mill WARNING! No warranty or complaint will be accepted in the case of damage to the device when grinding tools are used which are not original accessories of the device. WARNING! Before starting the machine, ensure that the grinding discs are correctly mounted and that there are no loose parts inside the device. If this is not observed, no warranty or complaint will be accepted for damage to the device or personal injury that result.
Working with the disc mill 5.1 Display and control panel If the grinding chamber is open, the button (h) to lock the grinding chamber is not lit up! During the motorised closing of the grinding chamber, the button (h) flashes green until the grinding chamber is closed. It is then lit up in green. When starting up, the start button (e) flashes green. When the device has started up, it lights up in green. After stopping the device, the stop button (f) flashes red until the disc comes to a standstill.
Working with the disc mill Menu change Selecting menu items 1. To move from the "Parameter" menu to the "Check/Setup" menu, actuate the arrow buttons (c, d) until the - and + signs which are visible on the bottom right of the display are highlighted in black! Then use the buttons + (a) or - (b) to move to the Check/Setup menu! 2. The menu change from the Check/Setup menu to the Parameter menu takes place in the same way. 1. The menu items within menus are selected using the arrow buttons (c, d). 5.
Working with the disc mill 3. To change the grinding gap to adjust the zero point, the zero point line must be selected in the Check / Setup menu using the arrow buttons (c, d). 4. Remove the suction flange lid (11). Check both grinding discs while they are moving together through this opening. It should only be possible to see a minimal light gap between the two discs. During the process of setting the zero point, no gap information is shown on the display.
Working with the disc mill 1. To move from the "Check/Setup" menu to the "Parameter" menu, actuate the arrow buttons (c, d) until the - and + signs which are visible on the bottom right of the display are highlighted in black! Then use the buttons + (a) or - (b) to move to the Parameter menu 2. Close the grinding chamber! 3. In the Parameter menu, press the c button (arrow up) until the line to enter the gap width is highlighted. 4.
Working with the disc mill 1. To move from the "Parameter" menu to the "Check/Setup" menu, actuate the arrow buttons (c, d) until the - and + signs which are visible on the bottom right of the display are highlighted in black! Then use the buttons + (a) or - (b) to move to the Check/Setup menu! 2. Select reverse using the arrow buttons (c, d), and activate (on) or deactivate (off) reverse operation with + (c) or - (d) button.
Working with the disc mill 2. Select the Time menu item using the arrow buttons (c, d) and then adjust using the + / - button. If no grinding duration has been specified, the grinding can be started and ended manually using the start - (e) and stop- (f) button. The maximum timecontrolled grinding duration that can be set is 60 min! 5.7 Changing the language 1.
Working with the disc mill 3. The hardness of the zirconium oxide grinding disc is MOHS 8.5 (HV1350). No sample material that is harder may be ground because this causes the outer edges of the grinding disc to chip. Chipping of the edges can also occur with a sample material with MOHS hardness of 6 or 7. 4. Proceed very carefully when grinding using zirconium oxide grinding discs.
Working with the disc mill Before switching the device on, care must be taken that the grinding chamber is locked and the sample material container is placed straight in the insert and is not twisted! CAUTION! Switch the device on before filling material in the hopper. 1. The cover of the hopper is secured by a quarter turn quick release fastener. To open the lid, turn the quick release fastener a quarter turn in an anticlockwise direction! 2. Fill the sample in the hopper 3.
Working with the disc mill NOTICE! The grinding disc support and the housing are made from ductile cast iron. This cast steel is not rustproof. If you grind slightly damp sample material, after grinding you must dry the back of the grinding disc, the inside of the grinding disc support and all parts of the housing which come into contact with the sample. If you do not do so, corrosion can be expected to occur. 5.
Cleaning 6 Cleaning DANGER! Mains voltage! - Before starting cleaning work, unplug the device and protect it from restarting accidentally! - Do not let liquid run into the device. - Indicate cleaning work using a warning sign. - Put safety equipment back into operation after cleaning work. NOTICE! The grinding disc support and the housing are made from ductile cast iron. This cast steel is not rustproof.
Cleaning WARNING! Risk of poisoning and fire! When using detergents which are flammable or harmful to health, it is essential to heed the valid safety regulations (TLV) and where applicable to clean the disc mill in a ventilated safety zone. 6.3 Housing The machine can be cleaned outside when switched off using a soft damp cloth. A solution of water and mild detergent may be used here. No not use a solvent for cleaning. 6.
Servicing 7 Servicing DANGER! Mains voltage - Before starting servicing work, unplug the device and protect it from restarting accidentally! - Indicate servicing work using a warning sign. - Only have servicing carried out by skilled personnel. - Put safety equipment back into operation after servicing and repair work. - We recommend keeping a safety logbook into which all work (servicing, repairs etc.) to the device are entered.
Servicing Function part Task Test Service interval Grinding chamber sensor Start inhibitor Open grinding chamber; start; error message Always before use Grinding chamber safety interlock Start inhibitor Do not close grinding chamber electrically; start; error message Always before use Grinding container protective equipment Start inhibitor Sample material container not inserted; start; error message Always before use Grinding disc gap width Crush function Check distance Always before use
Servicing 5 CAUTION! - Risk of crushing when changing the grinding discs. - When changing grinding discs, secure them to prevent them falling down. 6 CAUTION! Before inserting the new discs, clean the support and the back of the discs thoroughly. This is in particular very important when using the ZrO2 discs and also with TC+CO discs, so that the discs are positioned without tension and parallel to each other.
Servicing DANGER! Ensure that the plug is removed from the socket again after step 5! 1. Connect the device to the power supply! 2. 3. Switch the main switch (3) to I (ON)! To ensure that the hexagon screws at the back of the movable grinding disc can be reached, the grinding gap should be moved to the smallest width (see chapter “Adjusting the gap width”) 3 4. Then press the release button (h) on the control panel. 5. The grinding chamber interlock (8) is released! Now open the grinding chamber.
Servicing 7. Then hold the motor shaft in place with the help of the motor shaft retainer (s). CAUTION! Do not lock the motor shaft retainer (s) by resting on the component! NOTICE! Hold grinding discs securely when changing them and do not let them fall. This can lead to breaking or chipping in the case of zirconium oxide discs. 8. CAUTION! Risk of crushing when changing the grinding discs. Ensure that the grinding disc does not fall on the floor.
Servicing 9. The fill hopper (4) must be removed to dismantle the fixed grinding disc (5). 10. To do this, manually close the grinding chamber and remove the 3 cylinder screws shown. 11. Remove hopper from the front.
Servicing 12. DANGER! Risk of crushing when changing the grinding discs. Ensure that the grinding disc does not fall on the floor. Loosen the 2x M20 mounting screws using the ratchet wrench and open the grinding chamber. Hold the grinding disc in place. Remove the hexagon screws and remove the grinding disc. 13. Now take the replacement moving grinding disc and assemble with the hexagon screws (see Point 5 + 6 in reverse order) 14. Install the housing cover 15. Connect the mains plug again. 16.
Servicing Material Max. guide value tightening torque (Nm) Density g/cm³ Abrasion resistance Use for sample material Hardened steel 1112% Cr At least 50 7.9 Good Hard, brittle samples Manganese steel 12-13% Mn At least 50 7.9 - 8 Good Hard, brittle samples Tungsten carbide 90.3% TC + 9.5% CO At least 50 14.8 Very good Hard, abrasive samples Zirconium oxide 92.5 ZrO2 Approx. 20 5.
Servicing 7.3 Replacing the gear oil The gearbox of the motor is filled with gear oil on delivery (ISO VG 220). A removable fill screw (o) is present in the top of the gearbox housing to change the gear oil. To reach this the housing cover must be removed. This oil must be changed after approx. 5 years. 7.3.1 Conducting the gear oil change 1. Run the DM400 for approx. 15 minutes so that the gear oil inside warms up and drains off better. 2. Switch the device off and unplug.
Servicing 50 5. Hold a flat container underneath the oil drain plug (n) and unscrew this using an Allen Key No. 5 until oil flows out. 6. Allow all of the oil to drain from the gearbox (approx. 0.22 l). Watch the size of the collecting container and empty at intervals where necessary, screwing the oil drain plug back in to do so. 7. When the gear oil has been completely emptied, remove the oil drain plug! 8.
Repair 8 Repair DANGER! Mains voltage! - Before starting repair work, unplug the device and protect it from restarting accidentally! - Indicate repair work using a warning sign. - Have all repair work conducted by skilled personnel. - Put safety equipment back into operation after servicing and/or repair work.
Repair 8.
Repair 53
Disposal 9 Disposal Observe the respective statutory regulations when disposing of the device. Information on disposal of electrical and electronic devices in the European Community: The disposal of electrical equipment within the European Community is specified by national regulations based on EU Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE). Accordingly all equipment supplied after 13.08.
EC Declaration of Conformity 10 EC Declaration of Conformity 55
EC Declaration of Conformity 56
Index 11 Index A M Accident prevention .............................................. 9 Material feed .......................................................36 Adapting to the mains network ........................... 26 Menu change ......................................................31 Adjusting the gap width ...................................... 32 Menu navigation .................................................30 Adjusting the grinding time .................................
Index 58
FB-EW-805-042 Änderungsstand D 01.
Copyright ® Copyright by Retsch GmbH Haan, Retsch-Allee 1-5 D-42781 Haan Federal Republic of Germany
