Retsch Emax User manual

© Retsch GmbH, 42781 Haan, Retsch-Allee 1-5, Germany | 20.01.2020 Version 0009
Manual
High Energy Ball Mill Emax
Translation

2
Copyright
© Copyright by
Retsch GmbH
Retsch-Allee 1-5
42781 Haan
Germany

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Table of Contents
1Notes on the manual............................................................................................................................. 7
1.1 Explanation of signs and symbols ..................................................................................................... 7
1.2 Disclaimer.......................................................................................................................................... 7
1.3 Copyright............................................................................................................................................ 7
2Safety...................................................................................................................................................... 8
2.1 Explanations of the Safety Instructions ............................................................................................. 9
2.2 General Safety Instructions ............................................................................................................. 10
2.3 Repairs............................................................................................................................................. 11
2.4 Confirmation Form for the Managing Operator................................................................................ 12
3Technical Data..................................................................................................................................... 13
3.1 Protective Equipment....................................................................................................................... 13
3.2 Degree of Protection........................................................................................................................ 13
3.3 Emissions......................................................................................................................................... 13
3.4 Electromagnetic Compatibility (EMC).............................................................................................. 14
3.5 Rated Power.................................................................................................................................... 14
3.6 Motor Rotation Speed...................................................................................................................... 14
3.7 Dimensions and Weight................................................................................................................... 14
3.8 Required Floor Space...................................................................................................................... 14
3.9 Receptacle Volume.......................................................................................................................... 14
3.10 Feed Grain Size............................................................................................................................... 15
3.11 Cooling............................................................................................................................................. 15
3.11.1 Internal..................................................................................................................................... 15
3.11.2 External.................................................................................................................................... 15
4Packaging, Transport and Installation .............................................................................................. 16
4.1 Packaging........................................................................................................................................ 16
4.2 Transport.......................................................................................................................................... 16
4.3 Temperature Fluctuations and Condensation ................................................................................. 16
4.4 Conditions for the Installation Site................................................................................................... 16
4.5 Electrical Connection....................................................................................................................... 18
4.6 Type Plate Description..................................................................................................................... 18
4.7 Removing the Transportation Lock.................................................................................................. 19
4.8 Removing the Transportation Aid.................................................................................................... 21
5First Commissioning........................................................................................................................... 23
5.1 Commissioning of the Cooling......................................................................................................... 23
5.2 Connection to an External Cooler.................................................................................................... 26
5.3 Cooling Surfaces of the Grinding Jar............................................................................................... 27
6Operating the Device .......................................................................................................................... 29
6.1 Use of the Device for the Intended Purpose.................................................................................... 29
6.2 Principle of Operation ...................................................................................................................... 30
6.3 Views of the device.......................................................................................................................... 30
6.3.1 Front............................................................................................................................................. 30
6.3.2 Back............................................................................................................................................. 32
6.4 Switching On / Off............................................................................................................................ 33
6.5 Opening and Closing of the Device................................................................................................. 33
6.5.1 Opening ....................................................................................................................................... 33
6.5.2 Closing......................................................................................................................................... 33
6.6 Emergency Unlocking...................................................................................................................... 34
6.7 Opening and Closing the Grinding Jar Support............................................................................... 35
6.7.1 Opening ....................................................................................................................................... 35
6.7.2 Closing......................................................................................................................................... 36
6.8 Opening and Closing the Grinding Jar ............................................................................................ 38
6.8.1 Closing......................................................................................................................................... 38

4
6.8.2 Opening ....................................................................................................................................... 39
6.8.3 Grinding Jar Identification............................................................................................................ 39
6.9 Ball Sizes and Speeds..................................................................................................................... 39
6.9.1 Recommended Ball Sizes............................................................................................................ 39
6.9.2 Recommended Grinding Jar Filling ............................................................................................. 40
6.9.3 Recommended Speeds ............................................................................................................... 40
6.10 Inserting the Grinding Jar ................................................................................................................ 40
6.11 Wet Grinding with Highly Flammable Materials............................................................................... 42
7Controlling the Device ........................................................................................................................ 43
7.1 Operating Controls, Displays and Functions................................................................................... 43
7.2 Operating Modes and Navigation.................................................................................................... 45
7.2.1 Navigation between Operating Modes ........................................................................................ 45
7.3 Grinding Parameters........................................................................................................................ 45
7.3.1 Adjustable Parameters ................................................................................................................ 45
7.3.2 Activatable or Deactivatable Parameters .................................................................................... 47
7.4 Manual Mode................................................................................................................................... 47
7.4.1 Start Process ............................................................................................................................... 47
7.4.2 Stop Process................................................................................................................................ 48
7.4.3 Pause Process............................................................................................................................. 48
7.5 Programme Mode............................................................................................................................ 48
7.5.1 Select a Programme.................................................................................................................... 49
7.5.2 Programme Heading and Description ......................................................................................... 49
7.5.2.1 Display of the Programme Description................................................................................ 49
7.5.2.2 Editing of the Programme Description and Heading ........................................................... 49
7.5.3 Edit a Programme........................................................................................................................ 50
7.6 Sequence Mode............................................................................................................................... 51
7.6.1 Select a Sequence....................................................................................................................... 52
7.6.2 Sequence Heading and Description............................................................................................ 52
7.6.2.1 Display of the Sequence Description................................................................................... 52
7.6.2.2 Editing of the Sequence Description and Heading.............................................................. 52
7.6.3 Edit a Sequence .......................................................................................................................... 52
7.6.3.1 Add a Programm to a Sequence ......................................................................................... 52
7.6.3.2 Change a Programm of a Sequence................................................................................... 52
7.6.3.3 Delete a Programm from a Sequence................................................................................. 53
7.7 Settings............................................................................................................................................ 53
7.7.1 Languages................................................................................................................................... 55
7.7.2 Date and Time ............................................................................................................................. 55
7.7.3 Signal Tone.................................................................................................................................. 55
7.7.4 Automatic Opening ...................................................................................................................... 55
7.7.5 Extended Time............................................................................................................................. 55
7.7.6 Temperature Limits...................................................................................................................... 56
7.7.6.1 Grinding with Activated Temperature Limits........................................................................ 57
7.7.6.2 Warning of Hot Grinding Jars .............................................................................................. 57
7.7.7 Timer Settings.............................................................................................................................. 58
7.7.7.1 Setting the Timer ................................................................................................................. 58
7.7.7.2 Start Grinding with Timer..................................................................................................... 58
7.7.8 Copy Logbook.............................................................................................................................. 59
7.7.9 Cleaning Mode............................................................................................................................. 59
7.7.9.1 Automatic Cleaning Mode.................................................................................................... 59
7.7.10 Operating Hours....................................................................................................................... 60
7.7.11 Software Versions.................................................................................................................... 60
7.7.12 User Information ...................................................................................................................... 60
7.7.13 Service Environment................................................................................................................ 60

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8Error Messages and Information Notes............................................................................................ 61
8.1 Error Messages ............................................................................................................................... 61
8.2 Information Notes ............................................................................................................................ 62
8.3 Return for Service and Maintenance............................................................................................... 63
9Cleaning, Wear and Maintenance ...................................................................................................... 64
9.1 Cleaning........................................................................................................................................... 64
9.1.1 Cleaning of the Grinding jar......................................................................................................... 64
9.1.2 Drying the Grinding Jars.............................................................................................................. 65
9.2 Wear ................................................................................................................................................ 65
9.3 Maintenance .................................................................................................................................... 65
9.3.1 Exchange of the Coolant ............................................................................................................. 65
9.3.1.1 Removing the Coolant and Rinsing the Cooling System..................................................... 65
9.3.1.2 Filling New Coolant.............................................................................................................. 67
9.3.2 Replacing the Fuses.................................................................................................................... 68
10 Accessories ......................................................................................................................................... 69
10.1 Aeration Lid...................................................................................................................................... 69
10.1.1 Cleaning the Aeration Lid ........................................................................................................ 70
11 Disposal................................................................................................................................................ 72
12 Index ..................................................................................................................................................... 73

Notes on the manual
6

Notes on the manual
7
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 these guidelines 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 0009 of the "High Energy Ball Mill Emax" manual has been prepared
in accordance with the Machinery Directive 2006/42/EC.
1.1 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
1.2 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.
1.3 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.

Safety
8
2 Safety
Safety Officer
The operating company itself must ensure the following with respect to persons authorised to
work on the device:
−that they have read and understood all regulations contained in the chapter on safety;
−that they are aware before they start work of all instructions and regulations for the target
group related to the work;
−that they have easy access to the manual for this device at all times;
−that they have been familiarised with the safe and correct handling of the device before
starting work on it, by means of a verbal introduction by a competent person and/or using
this manual.
Improper operation can lead to personal injuries. The operating company itself is
responsible for its safety and that of its staff. The operating company itself must ensure that no
unauthorised persons have access to 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.
People under the influence of intoxicating substances (medications, drugs, alcohol) or who
are overtired may not operate the device or work on the device.

Safety
9
2.1 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.

Safety
10
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.
2.2 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.
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.

Safety
11
2.3 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:

Safety
12
2.4 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
13
3 Technical Data
3.1 Protective Equipment
−This device is equipped with an automatic hood lock. The lock prevents the device from
being started when in an unsafe state.
−The device can only be started when the hood is closed.
−It is only possible to open the hood when the device has come to a halt.
−The grinding jar support (clamping lever) is permanently monitored before starting and
during the grinding process.
3.2 Degree of Protection
−IP30
3.3 Emissions
CAUTION
C.0020
Risk of injury caused by not hearing acoustic signals
Loud grinding noise
−Loud grinding noise may result in not hearing acoustic warning signals,
leading to injuries.
•Take the volume of grinding noise into consideration when
designing the acoustic signals in the working environment.
•Where necessary, use additional visual signals.
CAUTION
C4.0077
Risk of hearing loss
High sound level
−The sound level may be high depending on the type of material, the
number of balls used, the set grinding frequency and the grinding time.
Excess noise in terms of intensity and duration can lead to impairments or
permanent damage to hearing.
•Ensure you take suitable soundproofing measures.
•Wear hearing protection if there is loud or lasting noise.
Sound parameters:
The sound parameters are also influenced by the properties of the sample material.
Example 1:
Container:
2 steel grinding jars (125 ml)
Grinding body:
50 steel balls each (10 mm)
Feed material:
Quartz sand (~ 0.5 mm)
Feed quantity:
60 ml
Speed:
2 000 rpm
At these operating conditions, the workplace related equivalent continuous sound level
Leq = 83 dB(A).

Technical Data
14
Example 2:
Container:
2 zirconium grinding jars (125 ml)
Grinding body:
275 g ZrO2balls each (2 mm)
Feed material:
Quartz sand (~ 0.5 mm) plus
water (35 ml)
Feed quantity:
40 g
Speed:
1 500 rpm
At these operating conditions, the workplace related equivalent continuous sound level
Leq = 76 dB(A).
3.4 Electromagnetic Compatibility (EMC)
−EMC class according to DIN EN 55011: A
3.5 Rated Power
~ 3 100 W (VA)
3.6 Motor Rotation Speed
−Motor rated speed: 300 –2 000 revolutions per minute (rpm)
−Adjustable as required
3.7 Dimensions and Weight
−Height: 525 mm
−Width: 625 mm
−Depth: 645 mm
−Weight: ~ 120 kg (without grinding jars)
3.8 Required Floor Space
CAUTION
C5.0047
Risk of injury caused by the device falling down
Incorrect installation of the device
−Due to its weight, the device can cause injuries if it falls down.
•Only operate the device on a sufficiently large, strong and stable
workstation.
•Ensure that all of the device feet are securely supported.
−Height with open hood: ~ 945 mm
−Width of the base: 625 mm
−Depth of the base: 655 mm
Location requirements:
The device must be placed on a vibration-free and stable surface.
3.9 Receptacle Volume
The receptacle volume (feed volume) depends on the sample material and on the device
configuration and setting.

Technical Data
15
−Feed volume: max. 2 x 50 ml
3.10 Feed Grain Size
The feed grain size depends on the sample material and on the device configuration and
setting.
−Feed grain size: ≤5 mm
3.11 Cooling
Please refer to chapter "Commissioning of the Cooling" for detailed information on the
commissioning of the internal and external cooling.
3.11.1 Internal
There is a coolant tank at the backside of the device which must be filled with coolant before
putting into operation.
−Fill volume: ~ 600 ml
−Coolant: clean, lime-free water plus coolant additive
3.11.2 External
An additional cooling can be connected at the back of the device.
−Maximum pressure: < 6 bar
−Minimum temperature of the cooling liquid: > 5 °C
NOTICE Only clean, lime-free water with a coolant additive (article no. 02.362.0027) is
permitted as cooling liquid. The temperature must not fall below the minimum value, as
otherwise the sealing gaskets of the cooling circuit can be damaged.

Packaging, Transport and Installation
16
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
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.
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.
4.4 Conditions for the Installation Site

Packaging, Transport and Installation
17
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.
−Installation height: max. 2 000 m above sea level
−Ambient temperature: 5 °C –40 °C
−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
18
4.5 Electrical Connection
WARNING
W2.0015
Risk to life caused by an electric shock
Connection to socket without a protective earth conductor
−Connecting the device to sockets without a protective earth conductor can
lead to life-threatening injuries caused by an electric shock.
•Always operate the device using sockets with a protective earth
conductor (PE).
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.
WARNING When connecting the power cable to the mains supply, use an external fuse that
complies with the regulations applicable to the place of installation.
−Check the type plate for details on the necessary voltage,frequency, and maximum
external current source fuse for the device.
−The listed values must agree with the existing mains supply.
−Only use the supplied power cable to connect the device to the mains supply.
4.6 Type Plate Description
Fig. 1: Type plate
1 Device designation
2 Year of production
3 Part number
4 Serial number
5 Manufacturer’s address
6 CE marking
7 Disposal label
8 Bar code
1
2
3
4
5
6
7
8
9
10
11
12
14
13

Packaging, Transport and Installation
19
9 Power version
10 Mains frequency
11 Capacity
12 Amperage
13 Number of fuses
14 Fuse type and fuse strength
In the case of queries please provide the device designation (1) or part number (3), as well
as the serial number (4) of the device.
4.7 Removing the Transportation Lock
WARNING
W3.0005
Risk of injury due to the device falling down
Lifting the device above head height
−The device can fall causing serious injuries when lifted above head
height.
•Never lift the device above head height!
Fig. 2: Unscrewing the transportation lock
Unscrew the screws on either side of the device (TP).
The transportation lock can also be used as transportation aid.
CAUTION The weight without grinding jars amounts approx. 120 kg. The device may only
be lifted by four people.
TP

Packaging, Transport and Installation
20
Fig. 3: Attaching lifting straps
The transportation aid can also be used for lifting the device with a crane.
Attach the lifting straps to the two transportation aids as shown in the figure.
NOTICE The housing can be damaged if the lifting straps are too short. The four lifting straps
must be sufficiently long in order to observe a minimum distance of 100 cm between the device
and the hoist.
Fig. 4: Minimum distance between housing and hoist
≥ 100 cm
(40 inches)