Exakt 80E Plus + User manual

Table of Contents
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27891EN-900-02 / Edition 02/2017
Article number:
27891EN
27891EN-900-02 / Edition 02/2017
EN
Translation of the original operating instructions, English
THREE ROLLER MILL
Operating Instructions
Document number / Edition

Table of Contents
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27891EN-900-02 / Edition 02/2017
1 TABLE OF CONTENTS
1Table of Contents 1
2Contact addresses 6
2.1. Manufacturer address 6
2.1.1. Imprint 6
2.2. Service and ordering spare parts 6
3Installation information in advance 7
4Safety 8
4.1. General information concerning safety 8
4.2. Safety symbols 9
4.3. Graphical conventions 10
4.4. Commissioning 11
4.5. Selection of location 11
4.6. Safety notes regarding operation 12
4.7. Safety notes regarding cleaning work 15
4.8. Handling chemical substances and coolants/lubricants 16
4.9. Cleaning agents 17
5Performance specifications 18
5.1. Intended use 18
5.2. No release for work in potentially explosive atmosphere 19
5.3. Reasonably foreseeable misuse 19
5.4. Qualification of the personnel 19
5.5. Technical condition 20
5.6. Protection against unintentional start 20
5.7. Safety devices 20
5.8. Safety warning notes 20
5.9. Marking 21
5.9.1. Type plate of the machine 21
5.9.2. Type plate of operating unit 23
6Technical data 24
6.1. Environment 24
6.2. Operating and auxiliary materials 24
6.3. Weights 24
6.4. Airborne sound emission 25
6.5. Dimensions 25
6.6. Dimensions Crate 25
6.7. Electric values EU 25
6.8. Electric values US 25
6.9. Electric values Japan 25

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6.10. IP protection 26
6.11. Roller temperature control 26
6.12. Rollers 26
7Unit description 27
7.1. Functional principle 27
7.2. Overview 28
7.2.1. Section view 28
7.3. Operating modes 29
7.3.1. Cleaning 29
7.3.2. Mixing 29
7.3.3. Gap-Gap 29
7.3.4. Gap-Force 30
7.3.5. Force-Force 30
7.4. Emergency stop 31
7.5. Safety devices 32
7.5.1. Cleaning 32
7.5.2. Routine operations 33
7.6. Safety marks 34
7.6.1. Danger of crushing 34
7.6.2. Danger of cuts 34
7.6.3. Voltage 35
7.6.4. Increased leakage current 35
7.6.5. Tempering fluid 36
7.7. Control elements 37
7.7.1. Front side 37
7.7.2. Backside 38
7.8. Roller temperature control 39
7.8.1. Pressureless cooling 40
7.8.2. Pressure cooling 42
7.9. Scraper system 43
7.10. Load traverse 43
7.11. Scope of delivery 44
7.12. Equipment variants 47
7.13. Safety devices nip gap and optional accessories 48
7.13.1. Safety devices 48
7.13.2. Optional accessories 49

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8Transport 51
8.1. Packaging symbols 51
8.2. Intermediate storage 52
8.3. Uncrating 52
8.4. Instructions for lifting 55
8.4.1. Moving the machine by hand 57
9Installation 58
9.1. Setup site 58
9.2. Dismounting the load traverse 60
9.3. Mounting and aligning the operating unit 61
9.4. Connecting the electric supply 62
9.4.1. Network configuration 62
9.4.2. Connect variant 1: fixed connection 63
9.4.3. Connection variant 2: fixed connection with coded heavy
duty connector 64
9.4.4. Connection variant 3: Connection via three-poles standard
plug (min. 15A) 66
9.5. Connecting the roller temperature control 68
9.5.1. Temperature control unit 68
9.5.2. With pressureless cooling 69
9.5.3. With pressure cooling 70
9.6. Checklist installation 70
10 Setup 71
10.1. Cleaning the machine housing 71
10.2. Scraper knife types 72
10.3. Mounting the scraper knife 73
10.3.1. Combination scraper knife –scraper bar - adaptor 75
10.4. Putting on the knife guard 76
10.5. Adjusting the scraper contact pressure 77
10.6. Mounting the scraper socket 78
10.7. Aligning the scraper socket in parallel to the roller 80
10.8. Setup of the scraper angle 81
10.9. Mounting the splash tray 82
10.10.Mounting the cleaning guard 83
10.11.Inserting plastic guides for working width 85 mm and 170 mm 85
10.12.Mounting plastic guides for working width 200 mm 87
10.13.Mounting the safety device nip gap, working widths 85 mm, 170 mm,
200 mm 90
10.14.Mounting hopper for working width 170 mm 91

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10.15.Mounting hopper for working width 200 mm 93
10.16.Mounting splash guards for working width 200 mm 94
10.17.Mounting splash guards for inner side paneling 95
10.18.Mounting the solvent dispenser for guide lubrication 96
11 Operating elements and operating unit 97
11.1. Main switch 97
11.2. Operating panel 98
11.3. Emergency stop button 99
11.4. Operating unit 100
11.4.1. Safety messages on the display 102
11.4.2. Overload messages on the display 104
11.5. Program structure 105
12 Operation 106
12.1. Switching on the machine 108
12.2. Cleaning the rollers 110
12.2.1. Pre-cleaning the rollers 110
12.2.2. Preparing for cleaning 110
12.2.3. Cleaning roller 1 112
12.2.4. Cleaning roller 2 and roller 3 112
12.3. Cleaning the scraper system 113
12.4. Temperature control of the rollers 113
12.5. Adjusting the rollers 114
12.6. Defining the pre-settings (setup) 115
12.6.1. Setup after every adjustment and before each programming 116
12.6.2. Select setup via menu item Select setting (in routine
operations) 117
12.7. Routine operations 119
12.8. Routine operations: Test run with petroleum jelly 121
12.8.1. Step 1 121
12.8.2. Step 2 121
12.8.3. Optimum product flow 122
12.9. Reverse function 124
12.9.1. Sequence from the cleaning mode 124
12.9.2. Sequence from routine operations 126
12.10.Checking the safety devices 127
12.10.1. Preparing for check 127
12.10.2. Checks functions 127

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13 Maintenance 128
13.1. Cleaning the machine housing 129
13.1.1. Cleaning the display of the operating unit 129
14 Maintenance and care 130
14.1. Service and maintenance plan 131
15 Troubleshooting 133
16 Shutting down 136
16.1. Short-term shutting down 136
16.2. Long-term shutting down 136
16.3. Putting out of operation 136
17 Disposal 137
17.1. Disposing of packaging 137
17.2. Disposing operating materials and cleaning agents 137
17.3. Disposing of unit 137
18 Spare and wear parts 138
18.1. Wear parts 80S Plus, 80E Plus 138
18.2. Spare parts 80S Plus, 80E Plus 141
19 Conformity check 144
19.1. Checking the conformity 144
20 Index 145
21 Annex 148
21.1. Warranty conditions 148
21.2. Declaration of conformity 149

Contact addresses
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2 CONTACT ADDRESSES
2.1. MANUFACTURER ADDRESS
EXAKT Advanced Technologies GmbH
Robert-Koch-Strasse 5
22851 Norderstedt
Germany
Phone:+49 (0) 40 / 529 560 - 0
Fax: +49 (0) 40 / 5 24 99 59
email: [e-mail]
http://www.exakt.de
2.1.1. IMPRINT
© EXAKT Advanced Technologies GmbH, Norderstedt
Layout:: EXAKT Advanced Technologies GmbH
Text layout: EXAKT Advanced Technologies GmbH
Illustrations: EXAKT Advanced Technologies GmbH
This documentation is copyrighted by EXAKT. Without prior written approval,
the documentation may not be copied or be used contrary to the legitimate
interests of EXAKT.
Subject to change without notice!
2.2. SERVICE AND ORDERING SPARE PARTS
In case of service questions and for ordering spare parts, please contact the
retailer by whom you purchased the unit.
For ordering spare parts, use the order form in chapter 18 Spare
and wear parts.

Installation information in advance
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27891EN-900-02 / Edition 02/2017
3 INSTALLATION INFORMATION IN ADVANCE
The installation information in advance shall give you all information you need
for preparing you site before the machine is delivered to you. It gives information
how to handle and transport the machine, information for the setup site and
electrical connection / preparation, etc.
For this, the relevant chapters in this operating instructions are shown in the
table below:
We additionally recommend to read the entire operating
instructions before the machine is delivered to you.
Especially when
ordered option
(article-no.)
Chapter
4 Safety
5.1 Intended use
5.2
No release for work in potentially explosive
atmosphere
5.9.1 Type plate of the machine
6 Technical data
7.6 Safety marks
8 Transport
9.1 Setup site
9.4 Connecting the electric supply
27106 & 27107
or
27108 & 27109
9.4.3 Connection variant 2: fixed connection with
coded heavy duty connector
9.5 Connecting the roller temperature control
27510
9.5.2 With pressureless cooling
27500
9.5.3 With pressure cooling

Safety
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4 SAFETY
Link back to chapter 3 Installation information in advance
4.1. GENERAL INFORMATION CONCERNING SAFETY
Every persons appointed to install, commission, operate, maintain and service
the unit and the associate components must have read and understood these
instructions and in particular the chapter Safety.
If necessary, special training appropriate to the professional qualification of the
persons in question shall be carried out.
Explanation of the symbols in these instruction:
DANGER
Indicates an exceptionally severe danger situation. Disregarding
this note will cause lethal or severe irreversible injuries.
WARNING
Indicates an exceptionally severe danger situation. Disregarding
this note can result in lethal or severe irreversible injuries.
CAUTION
Indicates a danger situation. Disregarding this note can cause
light or medium injuries.
NOTE
Indicates risk of property damage. Disregarding this note can cause
property damage.
Here you find important background information and
explanations within the current context and status information
within a sequence of action.

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4.2. SAFETY SYMBOLS
Symbol
Meaning
Warning of general and not categorized risks
Warning of voltage
Warning of rollers rotating reversely
Danger of cuts
Hot surface
Suspended load
Danger of hand injuries
Danger of crushing
Danger of tripping
Warning of toxic substances
Warnung of explosive substances
Symbol
Meaning
Use a spatula
Wear safety gloves
Wear foot protection
Wear eye protection
Wear protective clothing

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Wear protective apron / lab coat
Disconnect machine from the mains
Read operating instructions
Reference to other documents
4.3. GRAPHICAL CONVENTIONS
Symbol
Meaning
Tool
This symbol indicates that a
special tool or consumables are
required.

Bulleted list
Properties of the unit or
individual components are listed
in bulleted lists.
1.
›
Operating
sequence
Operating sequences instruct
you to perform something in a
given sequence.
Disposal
Notes for disposal of packaging
materials, wear parts and
defective unit parts.
Screwing tight
CW
Clockwise
(tightening the screw)
CCW
Counterclockwise (undoing the
screw)

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4.4. COMMISSIONING
The unit housing contains information signs that additionally enable safe
operation.
Observe all safety instructions without fail, observance serves your safety.
Prior to commissioning the unit, the operator must ensure that all safety-related
conditions are met.
Adhere to the relevant accident prevention regulations as well as other generally
accepted safety-related and occupational-medical regulations.
4.5. SELECTION OF LOCATION
The unit must be placed horizontally.
The installation location must ensure safe stand of the unit.
Place the unit on a fixed lab table that can bear the weight of the machine (see
chapter 6 Technical data).
NOTE
›Do not place any items on the unit.
›Before connecting the unit, check mains cable and power plug for damage.
›Connect the unit to the connection voltage specified on the type plate.
›Before connecting, compare the mains voltage to the unit voltage given on
the type plate of the unit.
›Only allow a trained electrician to connect the machine.
When selecting the location of installation, observe the corresponding safety
notes and manufacturer specifications for the operating materials used and/or
located in the surroundings of the unit.

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4.6. SAFETY NOTES REGARDING OPERATION
Refrain from any operation that:
›constitutes a danger for life and limb of the user or third parties,
›implies impairment of the unit or other property,
›impairs the safety and the functionality of the unit,
›disregards the specified safety instructions.
Maintenance and upkeep of the machine is only allowed to be carried out by
personnel trained and certified by EXAKT. These personnel must be familiar
with the machine and instructed on its dangers as well as have the required
qualification.
WARNING
Keep the machine housing closed during operation and only
open it to rectify functional faults and to perform maintenance
tasks.
Missing safety devices and covers must be attached again
immediately after finishing the work.
WARNING
Danger of injury in the area of the rotating rollers for persons
with long hair and/or wearing loose clothing, ties, scarves,
jewelry, bracelets, etc., in particular at the product nip gap
(gap 1)!
›Always use suitable safety devices.
›For all works, wear tight-fitting clothes and protect long hair by
headgear.
›Never wear ties, scarves, jewelry, bracelets, etc. for any work.

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WARNING
Danger of being pulled in by the rollers:
During operation, the rollers of the machine are driven.
This causes a danger of being pulled in.
›When working at the machine, pay attention to your hands and
fingers.
›For cleaning, set up the cleaning plate and change into cleaning
mode.
›Only use the machine with the provided safety devices.
›In routine operation, always work with the limiting jaws inserted to
the correct working width (according to the selected safety
device).
›In routine operation, supply or remove product only with the
spatula.
›Only use one-part spatulas or riveted spatulas with long handle.
›ALWAYS keep the spatula as far away as possible from gap 1
(nip gap roller 1 and roller 2).
WARNING
Danger of scalding:
Danger of scalding or burns at the media and at hot machine parts
when handling hot temperature control media.
›Before handling temperature control media, let them cool down.
›Wear safety gloves and protective clothing.
WARNING
Danger of eye injuries due to rotating rollers or when handling
product and cleaning agents
›In general, wear eye protection
›Wear suitable protective clothing

Safety
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CAUTION
Danger of cuts at the scraper knife.
›During assembly and handling, always work with plastic knife
protection or with knife protection for scraper socket.
›When working with the scraper socket and scraper knife, wear
suitable safety gloves.
CAUTION
Danger arising from the substances to be processed:
The substances to be processed can cause health hazards.
›Read the safety datasheets of the substances to be processed
carefully.
›Wear suitable protective clothing.
DANGER
When working at live connections, disconnect the machine from
the mains.
Inattentiveness can cause an electric shock.
When performing maintenance work at the electric system,
observe the following issues:
1. Switch off the voltage of the unit.
2. Secure against being switched back on.
3. Check that it is de-energized.
4. Earth and short circuit.
5. Cover neighboring live parts and secure danger area.

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4.7. SAFETY NOTES REGARDING CLEANING WORK
WARNING
Danger of being pulled in by the rollers:
During operation, the rollers of the machine are driven.
This causes a danger of being pulled in.
›When working at the machine, pay attention to your hands and
fingers.
›For cleaning, set up the cleaning plate and change into cleaning
mode.
›Only use the machine with the provided safety devices.
CAUTION
Danger of cuts at the scraper knife.
›During assembly and handling, always work with plastic knife
protection or with knife protection for scraper socket.
›When working with the scraper socket and scraper knife, wear
suitable safety gloves.
CAUTION
Danger arising from the substances to be processed:
The substances to be processed can cause health hazards.
›Read the safety datasheets of the substances to be processed
carefully.
›Wear suitable protective clothing.
NOTE
›When using cleaning agents, provide sufficient ventilation.
›Observe the safety data sheets of the substances to be processed.
›Observe the disposal instructions by the respective manufacturers.
›Observe local safety regulations.

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4.8. HANDLING CHEMICAL SUBSTANCES AND
COOLANTS/LUBRICANTS
When handling oil, grease and other chemical substances, observe the
corresponding safety data sheets and disposal instructions by the respective
manufacturers and take all local safety requirements into account.
CAUTION
When handling chemical substances such as cleaning agents,
cooling and temperature control media can cause hazards in
case of contact with skin or eyes as well as inhalation.
Provide suitable exhaust and wear safety goggles, safety gloves
and protective clothing.

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4.9. CLEANING AGENTS
When using cleaning agents, observe the corresponding safety data sheets and
disposal instructions by the respective manufacturers and take all local safety
requirements into account.
WARNING
Use of explosive or easily flammable cleaning agents constitutes
an increased danger of explosion.
Do not use explosive or easily flammable cleaning agents!

Performance specifications
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5 PERFORMANCE SPECIFICATIONS
5.1. INTENDED USE
Link back to chapter 3 Installation information in advance
Intended use of this machine is only defined for the fields of industry,
development, research and production for the quantities specified in the
technical data. Any other use is considered improper.
The spectrum of applications reaches from food industry to nanotechnology.
The unit is suitable for processing products in cosmetics, paints, electronics,
food, dental, ceramics, lubricants, adhesives, soap and special industries.
The intended use of the machine is the reduction of particle size and
dispensation of agglomerates, in rare cases the reduction of the primary particle
size.
Changes to the machine and its accessories are not permitted.
The machine is designed for operation by only one instructed person.
Only wear and spare parts approved by the manufacturer may be used.
Any use beyond the proper use specified above is considered improper. The
manufacturer is not liable for personal injury or material damage resulting from
use of the machine for other than the intended purpose.