Retsch ABP 250 User manual

© Retsch GmbH, 42781 Haan, Retsch-Allee 1-5, Germany | 05.12.2018 Version 0003
Manual
Jaw crusher and sample divider combination unit ABP 250
Translation

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Copyright
© Copyright by
Retsch GmbH
Retsch-Allee 1-5
42781 Haan
Germany

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Table of Contents
1Notes on the Manual........................................................................................................................ 6
1.1 Disclaimer .................................................................................................................................... 6
1.2 Copyright...................................................................................................................................... 6
1.3 Explanation of signs and symbols................................................................................................. 7
1.4 Explanations of the Safety Instructions.......................................................................................... 7
1.5 General Safety Instructions........................................................................................................... 8
1.6 Repairs....................................................................................................................................... 10
1.7 Responsibility of the operating company..................................................................................... 11
1.8 Personnel qualification and target group of this manual............................................................... 11
2Confirmation Form for the Managing Operator ............................................................................ 12
3Technical Data................................................................................................................................ 13
3.1 Intended use............................................................................................................................... 13
3.2 Protective Equipment.................................................................................................................. 13
3.3 Gap width................................................................................................................................... 13
3.4 Degree of Protection................................................................................................................... 13
3.5 Emissions................................................................................................................................... 13
3.6 Electromagnetic Compatibility (EMC).......................................................................................... 14
3.7 Rated Power............................................................................................................................... 14
3.8 Dimensions and Weight.............................................................................................................. 14
3.9 Required Floor Space................................................................................................................. 14
3.10 Feed Grain Size.......................................................................................................................... 15
3.11 Grinding chamber volume........................................................................................................... 15
3.12 Degree of hardness of the sample material................................................................................. 15
3.13 Installation drawing..................................................................................................................... 16
4Packaging, Transport and Installation.......................................................................................... 17
4.1 Packaging .................................................................................................................................. 17
4.2 Transport.................................................................................................................................... 17
4.3 Temperature Fluctuations and Condensation.............................................................................. 18
4.4 Conditions for the Installation Site............................................................................................... 19
4.5 Electrical Connection.................................................................................................................. 20
4.6 Type Plate Description................................................................................................................ 21
5First Commissioning...................................................................................................................... 22
5.1 Installation of the Device............................................................................................................. 23
5.2 Lubricating the device when putting it into service for the first time.............................................. 24
5.3 Use of the Device for the Intended Purpose................................................................................ 25
5.4 Principle of Operation ................................................................................................................. 26
5.5 Views of the Instrument .............................................................................................................. 27
5.5.1 Front....................................................................................................................................... 27
5.5.2 Part modules .......................................................................................................................... 28
5.5.3 Control element and display.................................................................................................... 28
5.5.4 Side view................................................................................................................................ 29
5.6 Settings...................................................................................................................................... 30
5.6.1 Adjusting the gap width........................................................................................................... 30
5.6.2 Setting the gap width .............................................................................................................. 31
5.7 Opening and closing the jaw crusher........................................................................................... 32
5.8 Dust extraction............................................................................................................................ 33
6Operating the device...................................................................................................................... 34
6.1 Opening the device..................................................................................................................... 34
6.2 Closing the device ...................................................................................................................... 34
6.3 Switching On / Off....................................................................................................................... 34
6.4 Inserting the part module............................................................................................................ 34
6.5 Preparing the sub-process.......................................................................................................... 35
6.6 Display unit................................................................................................................................. 37
6.7 Starting the crushing process...................................................................................................... 40

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6.8 Adding sample material .............................................................................................................. 40
6.9 Removing sample material after grinding .................................................................................... 41
7Cleaning, Wear and Maintenance.................................................................................................. 43
7.1 Cleaning..................................................................................................................................... 43
7.1.1 Removing and installing the feed hopper................................................................................. 44
7.1.2 Cleaning the feed hopper........................................................................................................ 44
7.2 Wear.......................................................................................................................................... 45
7.2.1 Replacing the breaking jaws ................................................................................................... 46
7.2.2 Replacing the wearing plates.................................................................................................. 47
7.3 Maintenance............................................................................................................................... 47
7.3.1 Lubricating the device............................................................................................................. 47
7.3.2 Checking the limit switch......................................................................................................... 48
8Return for Service and Maintenance............................................................................................. 49
9Accessories.................................................................................................................................... 50
10 Disposal.......................................................................................................................................... 51
11 Index............................................................................................................................................... 52

Notes on the Manual
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Notes on the Manual
6
1 Notes on the Manual
This Manual provides technical guidelines for the safe operation of the device. Read this
Manual through carefully before installing, putting into service and operating the device.
Reading and understanding this Manual is essential for handling the device safely and as
intended.
This Manual does not contain any repair instructions. Please contact your supplier or contact
Retsch GmbH directly if anything is unclear or you have questions about theseguidelines or the
device, or in the case of any faults or necessary repairs.
You can find further information about your device at http://www.retsch.com on the pages for
the specific device concerned.
Amendment status:
The document amendment 0003 of the "Jaw crusher and sample divider combination unit ABP
250" manual has been prepared in accordance with the Machinery Directive 2006/42/EC.
1.1 Disclaimer
This Manual has been prepared with great care. We reserve the right to make technical
changes. We assume no liability for personal injuries resulting from the failure to follow the
safety information and warnings in this Manual. No liability will be assumed for damage to
property resulting from the failure to follow the information in this Manual.
1.2 Copyright
This document or parts of it or its content may not be reproduced, distributed, edited or copied
in any form without prior written permission of Retsch GmbH. Damage claims shall be asserted
in the case of infringements.

Notes on the Manual
7
1.3 Explanation of signs and symbols
In this document the following signs and symbols are being used:

Reference to a recommendation and/or an important information

Reference to a chapter, table or figure

Action instruction
│Name│
Software menu function
[Name]
Software button
⟨Name⟩
Software checkbox
1.4 Explanations of the Safety Instructions
The following warnings in this Manual warn of possible risks and damage:
DANGER
D1.0000
Risk of fatal injuries
Source of danger
Possible consequences if the danger is ignored.
•Instructions and information on how to avoid the risk.
Fatal or serious injuries may result if the “Danger” sign is disregarded. There is a very high
risk of a life-threatening accident or lasting personal injury. The signal word DANGER is
additionally used in the running text or in instructions.
WARNING
W1.0000
Risk of life-threatening or serious injuries
Source of danger
Possible consequences if the danger is ignored.
•Instructions and information on how to avoid the risk.
Life-threatening or serious injuries may result if the “Warning” sign is disregarded. There is
an increased risk of a serious accident or of a possibly fatal personal injury. The signal word
WARNING is additionally used in the running text or in instructions.
CAUTION
C1.0000
Risk of injuries
Source of danger
Possible consequences if the danger is ignored.
•Instructions and information on how to avoid the risk.
Average to slight injuries may result if the “Caution” sign is disregarded. There is an average
or slight risk of an accident or personal injury. The signal word CAUTION is additionally
used in the running text or in instructions.

Notes on the Manual
8
NOTICE
N1.0000
Type of damage to property
Source of the damage to property
Possible consequences if the information is ignored.
•Instructions and information on how to avoid the damage to
property.
Damage to property may result if the information is disregarded. The signal word NOTICE is
additionally used in the running text or in instructions.
1.5 General Safety Instructions
CAUTION
C2.0002
Risk of injury
Lack of knowledge of the Manual
The Manual contains all safety-related information. Disregarding the
Manual can therefore lead to injuries.
•Read the Manual carefully before operating the device.
Target group
All those operating, cleaning or working with or on the device.
This device is a modern, powerful product from Retsch GmbH and has been developed in line
with the state-of-the art. The device is safe to use when operated correctly and when following
the instructions in this manual.
Safety Officer:
The operating company itself must ensure that people authorised to work on the device…
have read and understood all regulations contained in the chapter on safety;
are aware before they start work of all instructions and regulations for the target group
related to the work;
have easy access to the technical documentation for this device at all times;
have been familiarised with the safe and correct handling of the device before starting
work on it, bymeans of a verbal introduction by a competent person and/or using this
technical documentation.
CAUTION Improper operation can lead to personal injuries and damage to property. The
operating company itself is responsible for its own safety and that of its staff. The operating
company itself is responsible for ensuring that no unauthorised persons have access to the
device.
CAUTION People under the influence of intoxicating substances (medications, drugs,
alcohol), fatigue or health disorders are not allowed to operate the device.

Notes on the Manual
9
CAUTION
C3.0015
Risk of injury
Improper modifications to the device
Improper modifications to the device can result in injuries.
•Do not make any unauthorised changes to the device.
•Only use the spare parts and accessories approved by Retsch
GmbH!
NOTICE
N2.0012
Changes to the device
Improper modifications
The conformity declared by Retsch GmbH with the European Directives
will lose its validity.
Any warranty claims will be terminated.
•Do not make any modification to the device.
•Use spare parts and accessories that have been approved by Retsch
GmbH exclusively.

Notes on the Manual
10
1.6 Repairs
This manual does not contain any repair instructions. For safety reasons, repairs may only be
carried out by Retsch GmbH or an authorised representative or by qualified service technicians.
In case of repair, please inform…
…the Retsch GmbH representative in your country,
…your supplier, or
…Retsch GmbH directly.
Service address:

Notes on the Manual
11
1.7 Responsibility of the operating company
The company operating the machine is responsible for ensuring that every person working with
the machine has been given precise instructions on the basis of this manual (commissioning,
operation, servicing). Training for operating staff must include the following points:
•Intended use of the machine
•Hazard areas
•Safety regulations
•The company must be satisfied that staff have the required qualifications
•General instructions and what to do in an emergency
•Applicable accident prevention regulations
•Personal protective clothing required
•Operation of the machine according to this manual
•Recognised, applicable rules governing health and safety
Involve ABP 250 in your emergency planning:
•Integrate ABP 250 in your operating instructions regulating conduct in
emergency situations.
•Integrate ABP 250 in your risk assessment in acc. with the German
Ordinance on Industrial Safety and Health (BetrSichV) to prevent accidents
during work processes.
•Consider fire-fighting measures, tackling the effects of leaking substances,
possible radiation, rescuing people, first-aid measures.
1.8 Personnel qualification and target group of this manual
This manual is intended for trained assembly personnel , maintenance staff and users .
Training must be provided in the language of the personnel concerned so that all instructions
are understood. As such the following personnel qualifications are necessary:
Assembly,
commissioning,
instruction,
troubleshooting,
servicing work,
as described in this
manual
Skilled technical staff as well as external service providers who
speak German and the language of the operating personnel.
The usual skills communicated during training, e.g. as a plant
fitter, mechatronics engineer or toolmaker, are prerequisites for
the assembly, commissioning and troubleshooting of the
machine. Employees must be able to manage all applicable
mechanical tasks and be familiar with and have experience of
dealing with these.
Operation
Education/training in accordance with the above section,
responsibilities of trained employees.
Servicing/repairs
They must be experienced, trained professionals, familiar with
requirements and guidelines.

Confirmation Form for the Managing Operator
12
2 Confirmation Form for the Managing Operator
This manual contains essential instructions for operating and maintaining the device which must
be strictly observed. It is essential that they be read by the user and by the qualified staff
responsible for the device before the device is commissioned. This manual must be available
and accessible at the place of use at all times.
The user of the device herewith confirms to the managing operator (owner) that he has received
sufficient instructions about the operation and maintenance of the system. The user has
received the manual, has read and taken note of its contents and consequently has all the
information required for safe operation and is sufficiently familiar with the device.
The managing operator should for legal protection have the user confirm the instruction about
the operation of the device.
I have read and taken note of the contents of all chapters in this manual as well as all
safety instructions and warnings.
User
Surname, first name (block letters)
Position in the company
Place, date and signature
Managing operator or service technician
Surname, first name (block letters)
Position in the company
Place, date and signature

Technical Data
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3 Technical Data
3.1 Intended use
This device has not been designed as a production machine or for continuous operation, but
rather as laboratory device for operation in an 8-hour single shift.
The ABP 250 is suitable for grinding medium to hard substances as well as brittle and hard
ductile materials. The final fineness that can be achieved can be up to 2 mm and less
depending on the feed material.
The maximum feed size is <120 x 90 mm.
The following materials are examples of those that can be ground in the ABP 250:
Concrete, ores, rock, glass, ceramics, coal, minerals, slag, cement clinker etc.
The performance data, throughput and the final fineness level that can be achieved depend on
the breaking properties and degree of hardness of the sample material and on the gap width
that has been set. They can only be empirically calculated.
The Retsch applications laboratory will be happy to provide any further information you require.
Any other use is considered to be improper and can lead to damage to property and even to
personal injuries.
3.2 Protective Equipment
This device may only be started once the door has been closed and the collecting receptacle
has been inserted in the base frame.
A limit switch behind the collecting receptacle prevents the device being started in an unsafe
state.
Pulling the collecting receptacle out results in the machine stopping immediately.
The door can only be opened once the collecting receptacle has been removed.
The motor protection switch turns the drive motor off if there is a blockage in the jaws.
3.3 Gap width
Gap width: 0 to 30 mm, adjustable using the threaded spindle
3.4 Degree of Protection
IP 54
3.5 Emissions
Noise levels:
The noise levels are influenced by the properties of the sample material.
Example:
Feed material:
Marble pebbles (< 50 mm)
Gap width:
< 1 mm
Final particle size
< 4 mm
Grinding chamber
filling level:
~ 65 %

Technical Data
14
Under these operating conditions, the workplace-related equivalent continuous sound level Leq =
84.7 dB(A).
CAUTION
C4.0020
Failure to hear acoustic signals
Loud noises during grinding
It is possible that acoustic warning signals and voice communication
cannot be heard.
•When planning the acoustic signals in the working environment, the
volume of noises arising during grinding should be taken into
consideration. It may be possible to use additional visual signals.
CAUTION
C5.0045
Damage to hearing
A high noise level may arise depending on the type of the material, the jaws
used and the duration of grinding
Excessive noise in terms of level and duration can cause impairments or
lasting damage to hearing.
•Suitable sound insulation measures must be provided or hearing
protection worn.
3.6 Electromagnetic Compatibility (EMC)
EMC class in accordance with DIN EN 55011: B
3.7 Rated Power
~ 3 000 W (VA), 3 Phasen, verschiedene Anschlussspannungen
3.8 Dimensions and Weight
Height: ~ 1,460 mm
Width: ~ 1,350 mm
Depth: ~ 710 mm
Weight: ~ 565 kg
3.9 Required Floor Space
Width of floorspace: 1,350mm
Depth of floorspace: 710 mm
No safety distance is necessary. To improve operability, you should plan to leave a space of
around 50 cm to the left of the machine and a space of 60 cm at the front.
Location requirements :
This floor-mounted device must be placed on a level, firm base.

Technical Data
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3.10 Feed Grain Size
Feed size: < 120 x 90 mm
Final fineness: < 2 mm
The feed size depends on the sample material.
3.11 Grinding chamber volume
~ 1 200 ml
3.12 Degree of hardness of the sample material
The degree of hardness of the sample material should be above 3 on the Mohs’ scale to
achieve effective grinding. The degree jaws should be harder than the sample material to
prevent increased wear on the jaws.

Technical Data
16
3.13 Installation drawing

Packaging, Transport and Installation
17
4 Packaging, Transport and Installation
4.1 Packaging
The packaging has been adapted to the mode of transport. It complies with the generally
applicable packaging guidelines.
NOTICE
N3.0001
Complaint or return
Keeping the packaging
Inadequate packaging and insufficient securing of the device can
jeopardise the warranty claim in the event of a complaint or return.
•Keep the packaging for the duration of the warranty period.
4.2 Transport
DANGER
D2.0001
Serious personal injury
Suspended loads
If dropped, the great weight of the device would result in serious injuries
or death.
•People must never stand below suspended loads!
NOTICE
N4.0017
Damage to components
Transport
Mechanical or electronic components may be damaged during transport.
•The device must not be knocked, shaken or thrown during transport.
NOTICE
N5.0014
Complaints
Incomplete delivery or transport damage
The forwarding agent and Retsch GmbH must be notified immediately in
the event of transport damage. It is otherwise possible that subsequent
complaints will not be recognised.
•Please check the delivery on receipt of the device for its
completeness and intactness.
•Notify your forwarding agent and Retsch GmbH within 24 hours.

Packaging, Transport and Installation
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Fig. 1: Transporting with forklift
The base frame of the ABP 250 enables it to be directly transported using a forklift or similar
device.
WARNING
W2.0001
Serious personal injury
Load too heavy
The device is extremely heavy, weighing 565 kg, which can lead to
serious personal injury when it is lifted.
•The device may only be lifted and transported using lifting gear!
CAUTION Only use suitable lifting gear that has been approved for the weight of the device.
The ABP 250 has a base frame using which the device can be lifted and transported with the
help of lifting gear.
Move lifting gear such as a forklift under the base frame.
Slowly lift the device using the lifting gear and stabilise it to prevent it from toppling over.
4.3 Temperature Fluctuations and Condensation
NOTICE
N6.0016
Damaged components due to condensation
Temperature fluctuations
The device may be exposed to substantial fluctuations in temperature
during transport. The ensuing condensation can damage electronic
components.
•Wait until the device has acclimatised before putting it into service.
Temporary storage:
Also in case of an interim storage the device must be stored dry and within the specified
ambient temperature range.

Packaging, Transport and Installation
19
4.4 Conditions for the Installation Site
A floorspace of 1190 mm wide and 630 mm deep is required. The opening of the feed hopper
is at a height of approx. 1430 mm.
The ABP 250 may only be installed on a level, firm base. Anchoring is not essential because
the free moments of inertia only pass barely perceptible vibrations on to the surroundings, but it
is possible using the drill holes in the feet.
Only operate the ABP 250 at an installation site with sufficient lighting.
Installation height: max. 2 000 m above sea level
Ambient temperature: 5 °C –40 °C
WARNING
W3.0003
Serious personal injury
Contact between moving jaws in the grinding chamber
Accidentally reaching into the grinding chamber and between moving jaws
can cause serious injuries to hands.
•Always operate the device with the feed hopper installed.
NOTICE
N7.0021
Ambient temperature
Temperatures outside the permitted range
Electronic and mechanical components may be damaged.
The performance data alter to an unknown extent.
•Do not exceed or fall below the permitted temperature range (5 °C to
40 °C ambient temperature) of the device.
Maximum relative humidity < 80 % (at ambient temperatures ≤31 °C)
For ambient temperatures UTbetween 31 °C and 40 °C, the maximum relative humidity value LF
linearly decreases according to LF= –(UT–55) / 0.3:
Ambient temperature
Max. rel. humidity
≤31 °C
80 %
33 °C
73.3 %
35 °C
66.7 %
37 °C
60 %
39 °C
53.3 %
40 °C
50 %
NOTICE
N8.0015
Humidity
High relative humidity
Electronic and mechanical components may be damaged.
The performance data alter to an unknown extent.
•The relative humidity in the vicinity of the device should be kept as
low as possible.

Packaging, Transport and Installation
20
4.5 Electrical Connection
WARNING
W4.0005
Danger to life due to electric shock or fire
Incorrect connection to the power supply may result in parts of the housing or
cables being live and in fires starting.
Serious injuries or death due to an electric shock.
Serious injuries or death due to fires.
•The device may only be connected by a qualified electrician.
NOTICE
N9.0022
Electrical connection
Failure to observe the values on the type plate
Electronic and mechanical components may be damaged.
•Connect the device only to a mains supply matching the values on
the type plate.
Information about the required voltage and frequency of the device can be found on the
type plate .
The device may only be connected to the power supply using the connection cable
supplied.
The circuit breaker for connecting the power cable to the power supply at the installation
site should be suitable for higher start-up current and correspond to a type C
characteristic (slow blow fuse).
NOTICE
N10.0005
Electrical connection
Wrong direction of rotation on drive motor
Electronic and mechanical components may be damaged.
Insufficient grinding of the sample material.
•Before putting into operation for the first time, check whether the
direction of rotation of the motor (fan direction of rotation) complies
with the direction arrow on the belt cover.