Retsch RS200 User manual

Operating Instructions for Vibratory Disc Mill
Type RS200
Retsch GmbH, 42781 Haan, Rheinische Str.36, Germany, Doc.Nr. D 98.725.9999

15.11.2006 Retsch GmbH 2 Doc. Nr. D 98.725.9998
Notes on these operating instructions......................................... 3
Warning instructions............................................................... 3
Repairs................................................................................. 3
Safety ......................................................................................... 4
Safety instructions ................................................................. 4
Safety instructions –summarised, part 1 .................................. 5
Safety instructions –summarised, part 2 .................................. 6
Confirmation ......................................................................... 7
Technical data ............................................................................ 8
Use according to the intended purpose...................................... 8
Milling cup –nominal volume................................................... 8
Maximum charged grain size ................................................... 8
Driving power........................................................................ 8
Motor speed .......................................................................... 8
Emissions ............................................................................. 9
Materials and analyses of milling tools ...................................... 9
Systems of protection ............................................................. 9
Protective equipment.............................................................. 9
Mode of operation .................................................................. 9
Machine dimensions ............................................................... 9
Required floor space............................................................... 9
Transport and installation........................................................... 10
Packing ................................................................................ 10
Transport.............................................................................. 10
Temperature variations........................................................... 10
Temperature variations........................................................... 11
Intermediate storage .............................................................. 11
Erection ................................................................................ 11
Parameters for the place of installation ..................................... 11
Ambient temperature: 5°C to 40°C........................................... 11
Atmospheric humidity ............................................................. 11
Installation height: max. 2000 m above sea level ....................... 11
Transport safety device........................................................... 11
Electrical connection............................................................... 12
Important instructions for electrical connection .......................... 13
Serial interfaces..................................................................... 13
Operation ................................................................................... 14
Connecting the power supply ................................................... 14
Opening / closing / emergency unlocking .................................. 14
Insertion and clamping of the milling set of the RS200 ................ 15
Preparation of the milling process............................................. 16
Before starting the RS200 ....................................................... 18
Suitable milling sets for the RS200 ........................................... 18
Milling set filling level ............................................................. 18
Guide values for material quantity and grain size ....................... 18
Cleaning the milling cups ........................................................ 19
Drying the milling cups ........................................................... 19
Operation via the display unit of the RS200 ............................... 20
Symbols in the display unit...................................................... 20
Setting possibilities via the display menu .................................. 21
Languages ............................................................................. 21
False language selection .......................................................... 21
Manual operation .................................................................... 21
Milling programme .................................................................. 21
Milling time ............................................................................ 21
Speed ................................................................................... 21
Speed with agate .................................................................... 22
Starting time .......................................................................... 23
Opening automatic .................................................................. 23
Warning sound ....................................................................... 23
Service .................................................................................. 23
Contrast / Brightness............................................................... 24
Date / Time............................................................................ 24
Stand-by monitor.................................................................... 24
Fault signals in the display ......................................................... 25
F02 to F13 ............................................................................ 25
General....................................................................................... 26
Cleaning ............................................................................... 26
Maintenance.......................................................................... 26
Maintenance of the rubber springs............................................ 26
Opening the cover.................................................................. 27
Wearing parts........................................................................ 27
Copyright.............................................................................. 27
Alterations ............................................................................ 27

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Notes on these operating instructions
These operating instructions for the vibratory disc mill, type
RS200, give all the necessary information with regard to the
areas mentioned in the contents.
Instructions are given for the definite target group(s) in
each area, in order to ensure safe operation of the RS200
for its intended purpose. Knowledge of the relevant section
is essential for safe, proper handling in each target group or
groups.
This technical documentation is intended as a reference and
instruction manual. The individual sections are complete in
themselves.
These operating instructions do not include repair
instructions. If repairs are necessary please contact your
supplier or Retsch GmbH direct.
http://www.retsch.com
Warning instructions
Warnings are given by the following symbols:
Injury to persons
Damage to equipment
Follow the instructions for use
Repairs
These operating instructions do not include repair
instructions. For your own safety repairs must be carried out
only by Retsch GmbH, an authorised agent or by Retsch
service technicians.
In this case please contact:
The Retsch agency in your country
Your supplier
Retsch GmbH directly
Your service address:

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Safety
The RS200 is an ultra-modern, highly efficient product of
Retsch GmbH, and corresponds to state of the art. If the
machine is used according to the intended purpose with a
knowledge of this technical documentation it is completely
safe and reliable to operate.
Safety instructions
As the operating authority it is your duty to ensure that all
persons charged with working on the RS200:
have read and understood all the instructions on safety,
from the beginning of work know all the instructions and
regulations for the target group relevant to their work,
have access to the technical documentation for this machine
at all times without problems.
New personnel should be familiarized with safe, proper
handling of the machine before beginning work on the
RS200, either by verbal instruction from a competent
person or through this technical documentation.
Improper operation can cause injury to persons or damage
to the equipment. Your are responsible for your own safety
and that of your employees.
Ensure that no unauthorised persons have access to the
RS200.
For your own safety have your employees confirm that they
have been instructed in operation of the RS200. The draft of
a suitable form is given at the end of the section on safety.
We exclude any claims for damages of any kind for injury to
persons and damage to equipment arising from non-observance of
the following safety instructions.

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Safety instructions –summarised, part 1
Safety instructions
We exclude any claims for damages of any kind for injury to persons and damage to equipment arising from non-observance
of the following safety instructions.
Use according to the intended purpose
Do not make any alterations to the machine and use only spare parts and accessories approved by Retsch. Otherwise the
Declaration of Conformity to the European directives declared by Retsch will lose its validity.
Furthermore this will lead to loss of any kind of guarantee claims.
Milling cup nominal volume
The filling quantity of the milling set must not exceed half of the nominal volume.
The rings used could otherwise become damaged.
Packing
Please keep the packing material for the duration of the guarantee period, since if you have a complaint and the equipment
is returned in inadequate packing your guarantee claim is at risk.
Transport
The RS200 must not be knocked, shaken or thrown during transport. Otherwise the electronic and mechanical components
can be damaged.
Temperature variations
If the RS200 is subjected to high temperature variations (e.g. during air transport) it must be protected against condensed
water. Otherwise there may be damage to the electronic components.
Supplied items
If the supplied items are incomplete and/or there is transport damage you must inform the transporter and Retsch GmbH
immediately (within 24 hrs). Later complaints may possibly be no longer considered.
Ambient temperature
If the temperature drops below or exceeds ambient temperature the electrical and mechanical components can become
damaged and performance data can change to an unknown extent.
Atmospheric humidity
At high atmospheric humidity the electrical and mechanical components can become damaged and performance data can
change to an unknown extent.
Electrical connection
If the values on the type plate are not observed the electrical and mechanical components can become damaged.
Electrical connection should be carried out only by a qualified electrician. Danger through current surge.
Serial interface
The serial interface cables must not be longer than 2.5 m.
If the cables are longer this can result in disturbances during transmission of data.
Connecting the power supply
Never start the RS200 without the clamped milling set.
Mechanical components can become damaged through high unbalance.
If the values on the type plate are not observed the electrical and mechanical components can become damaged.
Emergency unlocking
The emergency unlocking device must never be operated when the machine is running –only when the machine is at a
standstill and is disconnected from the mains supply.
Danger of injury through unbraked after-running of the drive.
Insertion and clamping of the milling set of the RS200
Never start the RS200 without the clamped milling set.
Mechanical components can become damaged through high unbalance.
Preparation of the milling process
Please take necessary measures, depending on the dangerous nature of your milling material, in order to avoid danger to
persons.
When removing and opening hot milling cups it is essential to wear protective gloves.
Danger of burning the hands.
Rub the rubber gasket in the clamping plate from time to time with talcum powder and do not leave the milling set in the
RS200 after milling.
Strongly heated milling sets can stick together with the rubber of the clamping plate and are very difficult to remove.
The filling quantity of the milling set must not exceed half of the nominal volume.
The rings used could otherwise become damaged.

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Safety instructions –summarised, part 2
Safety instructions when starting the RS200
Before starting the machine ensure that the milling set is clamped.
The milling set can be ejected. Danger of injury and damage to the equipment.
Tips for fine milling
When using easily flammable materials it is essential to observe the section „Wet milling of easily flammable materials”.
Danger of explosion.
Guide values for the material quantity
If the filling level of the milling set is too high or too low the milling result will be impaired and this can cause damage
(increased abrasion) to the milling set.
Please take necessary measures, depending on the dangerous nature of your milling material, to avoid danger to persons.
When removing and opening hot milling cups it is essential to wear protective gloves.
Danger of burning the hands.
Cleaning the milling cups
Do not subject milling cups with ceramic inserts to rapidly changing temperature differences when rinsing.
The ceramic units can crack through sudden temperature changes.
Wet milling of easily flammable materials.
Before using easily flammable materials as millling auxiliary agents it is essential to specify in writing the
explosion protection documentation of the EC-directive, according to article 118 and 118a, as laid down in
directive 89/391/EEC.
Cleaning
Do not clean the RS200 with running water.
Danger to life through current surge.
Use only a cloth moistened with water.
Solvents are not permitted.
Maintenance
Easy running of roller 1 on the closing pin is necessary for reliable closing via the automatic closing mechanism of the RS200.
Wearing parts
These operating instructions do not include repair instructions. For your own safety repairs should be carried out only by
Retsch GmbH, an authorised agent or service technicians.

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Confirmation
I have taken note of the section „Notes on these
operating instructions” and the section on “Safety”
__________________________________
Signature of operating authority
__________________________________
Signature of service technician

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Technical data
Machine type designation: RS200
Use according to the intended purpose
Retsch vibratory disc mills are used for rapid, loss-free, fine milling
of medium-hard, hard/brittle and hard/tough materials. Both dry
and wet milling operations can be carried out. Milling with solvents
is permitted. In this case, however, the supplementary notes in the
section „Wet milling with easily flammable materials“ must be
observed.
Soil samples, ores, coal, coke, corundum, metal oxides,
minerals, plant samples, slags, silicates, cement and many
other substances can be milled, easily, quickly and without loss.
These oscillating disc mills are used successfully in practically all
areas of industry and research, particularly where stringent
requirements are set on purity, quickness, fineness and
reproducibility.
They are not designed as production machines, but as laboratory
equipment, intended for 8-hour single shift operation.
Do not make any alterations to the machine and use only spare
parts and accessories approved by Retsch.
Otherwise the Declaration of Conformity with the European
directives declared by Retsch loses its validity. Furthermore this
will result in the loss of any kind of guarantee claims.
Milling cup –nominal volume
Special steel: 50 / 100 / 250 ml
Agate: 50 / 100 ml
Tungsten carbide: 50 / 100 ml
The filling quantity of the milling sets must not exceed half the
nominal volume.
The rings used could otherwise become damaged.
Maximum charged grain size
The maximum charged grain size depends on the milling cup
volume and the degree of hardness of the milling material.
Milling set 50 ml = max. grain size < 5mm
Milling set 100 ml = max. grain size <10mm
Milling set 250 ml = max. grain size <15mm
Driving power
1500 W
Motor speed
The speed is adjustable in the following range:
700 - 1500 min-1
For agate sets adjustment of a speed greater than 700 min-1 is not
possible.
If no milling set is clamped in position the speed is also limited to
700 min-1.

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Emissions
Noise characteristic values of RS200:
Noise measurement according to DIN 45635-31-01-KL3
The noise characteristic values are influenced mainly by the
machine speed, material to be milled and the milling set.
Workplace-related emission value LpAeq = up to 84 dB(A)
Noise power level LWA = 99 dB(A)
Conditions of measurement:
Milling set : 250 ml steel with ring (90/125) and Puk (65)
Milling material : 100g cement clinker, grain size <2mm,
6 milling aid tablets C20
Speed : 1450 min-1
Noise level measuring instrument: Brüel & Kjaer 2237 Controller
Materials and analyses of milling tools
See: www.retsch.com/english/docs/grinding_tools.pdf
Systems of protection
IP40
Protective equipment
The RS200 is fitted with an automatic lid shutting device which
prevents the machine being started in an unsafe condition. The
machine can be started only with the lid closed.
The lid can be opened only when the machine is at a standstill.
Mode of operation
S1
Operation with constant load, the duration of which is sufficient for the
thermal steady state condition to be reached (DIN VDE 0530 T1)
Machine dimensions
Height: up to approx. 1220 mm / width: 820 mm / depth: up to
approx. 780 mm
Weight : RS 200 net approx. 210 kg
Required floor space
Height (open hood): 1900 mm / width: 820 mm /
depth: 780 mm;
A safety distance of 100 mm on the rear side is necessary so that
the main switch can be operated.

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Transport and installation
Packing
Packing is adapted to the transport route and conforms to
the generally applicable packaging guidelines.
Please keep the packing material for the duration of the
guarantee period since if there is a complaint and the
machine is returned with inadequate packing your
guarantee claim will be at risk.
Transport
The RS200 (210 kg) is to be lifted and transported only
be the transport screws TS supplied with the machine.
(Fig. 2 Fitting the transport screws)
Net weight of RS200 approx. 210 kg
Lifting above head height is not permitted.
The RS200 must not be knocked, shaken or thrown
during transport. Otherwise the electronic and
mechanical components can become damaged.
Fig. 2 Fitting the transport screws

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Temperature variations
If temperature variations are high (e.g. during air
transport) the RS200 must be protected against
condensed water. Otherwise the electronic components
can become damaged.
Intermediate storage
Ensure that the RS200 is also stored dry during
intermediate storage.
Erection
Erect the RS200 on a firm base. Further parameters are given
in the section „Technical data”.
Net weight of RS200: approx. 210 kg
The machine must be locked in position before starting up.
For this purpose press the locking lever F of the two front
rollers downwards.
Parameters for the place of installation
Ambient temperature: 5°C to 40°C
If the ambient temperature drops below or exceeds these
values the electrical and mechanical components can become
damaged and performance data are changed to an unknown
extent.
Atmospheric humidity
Maximum relative humidity = 80% at temperatures up to 31°C,
decreasing linearly down to 50% relative humidity at 40°C.
At higher atmospheric humidity the electrical and mechanical
components can become damaged, and performance data are
changed to an unknown extent.
Installation height: max. 2000 m above sea level
Transport safety device
The driving unit of the RS200 is locked for transport.
Before starting up for the first time the two cheese-head
screws Z fitted under the rubber cover G must be
removed (Fig. 3 Transport safety device).
To do this lift the rubber cover G upwards and unscrew
the cheese-head screws. Then pull out the cheese-head
screws side wards together with the sleeve P (Fig. 4
Removing the transport safety device).
Keep the cheese-head screws for further transport.
Z
Z
G
Fig. 3 Transport safety device
Abb.1 Betriebsarten
F

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Electrical connection
Voltage and frequency for the RS200 are given on the
type plate.
Ensure that these values correspond to the available
power supply system.
Connect the RS200 to the power supply system using
the supplied connection cable.
Protection by external fusing is to be carried out when
connecting the mains cable to the power supply,
according to the regulations at the place of installation.
If the values on the type plate are not observed this can
cause damage to the electronic and mechanical
components.
Electrical connection should be carried out only by a
qualified electrician. Danger through current surge.
P
G
Fig. 4 Removing the transport safety device
device
Abb.1 Betriebsarten

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Important instructions for electrical connection
1. Electrical connection without a protective conductor PE is not
permissible.
2. The drive of your RS200 is fitted with a frequency converter. To
fulfil the EMC directive this is fitted with a line filter and shielded
cables to the motor. If your RS200 includes a fault-current
protective system, fault throwing may result through the anti-
interference wiring of the frequency converter when this is
switched on (switching on takes place each time the milling
chamber hood is closed). This can occur without there being a
fault on your RS200 or your mains installation.
According to state of the art selective a.c.-d.c. sensitive fault-
current protective systems are recommended for such cases. The
tripping current must be adequately dimensioned since
capacitive compensating currents occurring only for a short time
(shielded cables, line filter) when switching on can easily cause
fault throwing.
Under certain circumstances it may be necessary to operate the
RS200 without a fault-current protective system. In this case,
however, it should be checked whether this is inconsistent with
the local regulations of the electricity supply company or other
applicable institutions or standards.
If the values on the type plate are not observed this can
result in damage to the electrical and mechanical
components.
Serial interfaces
Inactive interface Sc for optional data communication
with an external device. This necessitates updating of
the software.
(Fig. 5 Serial interface)
The interface cables must not be longer than 2.5 m.
Longer cables can cause disturbances during transmission of
data.
Sc
Fig. 5 Serial interface

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Operation
Connecting the power supply
Ensure that the voltage and frequency of your mains supply
correspond to the values on the type plate of the RS200. The
mains supply must be fused up to at leasts 16A.
(Fig. 6 Receiving socket and main switch)
Plug the mains cable into the receiving socket Au on
the rear side of the equipment.
Plug the mains plug into the mains socket.
Switch on the main switch H.
Never start the RS200 without the clamped milling set.
Mechanical components can become damaged through
too high unbalance.
If the values on the type plate are not observed this can
result in damage to the electrical and mechanical
components.
When the RS200 is switched on for the first time the language
menu is displayed.
The language of your country must now be selected by
turning the control knob E. By pressing this knob selection is
confirmed and the display shows “Open lid”.
(Fig 7 Control panel)
Opening / closing / emergency unlocking
Opening
The following steps are necessary in order to insert the
milling cup(s) and to clamp it (these):
Connect RS200 to the mains supply
Switch on the main switch on the rear side
Press button A -
The safety closing device opens and the lid D can be swung
open. The milling chamber is now freely accessible.
Closing
Locking the milling chamber is possible only if the RS200 is
connected to the mains supply and the main switch on the
rear side of the machine is switched on.
Close the housing lid D
(Fig. 8 Housing lid)
A sensor senses the closing pin of the housing lid and the
motor-driven lid closing mechanism is switched on.
The housing lid D is automatically locked.
H
Au
D
Fig 6 Receiving socket and main switch
Fig7 Control panel
panel
Abb.7 Bedienfeld
E
A
Fig 8 Housing lid
Abb.7 Bedienfeld

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Emergency unlocking
A key for the machine is included in the delivery, with which
the RS200 can be manually opened if there is a power failure.
(Fig. 9 Emergency unlocking)
(I) Insert the (S) key into the (O) opening on the
right-hand side.
(II) To unlock the gear, the key must be pushed in
further with some degree of force. While pushing the
key in, turn it in a clockwise direction as far as it will
go.
The cover can now be opened.
The emergency unlocking device must never be operated
when the machine is running –only when the machine is at a
standstill and is disconnected from the mains supply.
Danger of injury through unbraked, after-running of the
drive.
Insertion and clamping of the milling set of the
RS200
Do not use the grinding jar if it has 4 identical 13-mm-
diameter boreholes on the bottom.
These grinding jars may only be used in RS200 devices that
do not have a change index after the serial number. This
means that if a change index (e.g. xxxxxxxxx-F) is specified
behind your device’s serial number, you may not use the
older grinding jar described in the above.
Older grinding jars with 4 identical boreholes on the bottom
(13mm) can be reworked free of charge.
Fig. 9 Emergency unlocking
Abb.7 Bedienfeld

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In the RS200 a Retsch milling set of volumes 50 / 100 / 250
ml and materials special steel / agate / tungsten carbide can
be used.
Never start the RS200 without the clamped milling set.
Mechanical components can become damaged.
Preparation of the milling process
Fit the milling cup with a disc and a ring. Two rings can
also be inserted, depending on the milling set.
Position the rings and disc as shown in the
illustration opposite.
(Fig. 10 Positioning the ring and disc)
The material to be milled is filled into the space R
between the milling cup wall and the first ring. For an
optimum milling result do not fill any material into the
space between the inner ring and disc.
(Fig. 11 Filling volume of milling cup)
Remove any residues of the milling material adhering to
the milling cup (e.g. with a brush).
Close the milling cup with the lid, not forgetting the seal.
Engage the milling set in the locking bolt B of the holding
device by turning slightly.
(Fig. 12 Locking bolt)
The milling set is clamped with the eccentric lever S
You can then close the hood and start the RS200
(Fig. 13 Eccentric lever)
Please take necessary measures, depending on the
dangerous nature of your milling material, to avoid danger
to persons.
S
B
R
Fig. 10 Positioning ring and disc
Abb.7 Bedienfeld
Abb.10 Platzierung Ring und
Scheibe
Abb.7 Bedienfeld
Fig.11 Filling volume of milling cup
Fig. 12 Locking bolt
Fig.13 Eccentric lever

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When removing and opening hot milling sets it is essential
to wear protective gloves.
Danger of burning the hands.
Rub the rubber gasket in the clamping plate from time to
time with talcum powder and do not leave the milling set in
the RS200 after milling.
Strongly heated milling sets can stick together with
the rubber in the clamping plate and are then very
difficult to remove.

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Before starting the RS200
The milling cup clamping device has proved itself for
many years, and is easy and reliable to handle. In order
to guarantee safety of the operator and a long service
life of the machine components the milling cups must
be clamped carefully.
Please remember that the RS200 is a milling machine
with a very high power input into the milling material;
therefore the milling cups must be fixed properly.
Before starting the machine ensure that the milling set is
clamped.
Milling set can be ejected; danger of injury and damage
to equipment.
Suitable milling sets for the RS200
Do not use the grinding jar if it has 4 identical 13-mm-
diameter boreholes on the bottom.
These grinding jars may only be used in RS200 devices that
do not have a change index after the serial number. This
means that if a change index (e.g. xxxxxxxxx-F) is specified
behind your device’s serial number, you may not use the
older grinding jar described in the above.
Older grinding jars with 4 identical boreholes on the bottom
(13mm) can be reworked free of charge.
The RS200 is suitable only for milling sets with a nominal
volume of 50 –250 ml.
These are available in the following materials:
Special steel 50/100/250ml
Free of heavy metal 100/250ml
Agate 50/100ml
Tungsten carbide 50/100ml
Zirconium oxide 50/100ml
The milling sets have been developed specially for extreme
test conditions, such as long-term trials, high mechanical
loading and maximum rotary speeds –also for mechanical
alloying.
Milling set filling level
Guide values for material quantity and grain size
Milling cup
nominal
volume
Max.
charged grain size
Sample quantity
max./recommende
d
50 ml
< 5 mm
< 50/35 ml
100 ml
< 10 mm
< 100/75 ml
250 ml
< 15 mm
< 250/150 ml
The milling set to be used is determined by the sample
volume and max. charged grain size. Selection of the milling
set material depends on the degree of hardness of the milling
material and the effect of possible abrasion on the
subsequent analysis.
Fig. 14 Milling sets

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If the filling level of the milling set is too high or too low the
milling result will be impaired and damage (wear increase) to
the milling set can result.
Please take necessary measures, depending on the dangerous
nature of your milling material, to avoid danger to persons.
When removing and opening hot milling cups it is essential to
wear protective gloves.
Danger of burning the hands.
Cleaning the milling cups
To clean the milling cups the seal between the lid and milling
cup must be removed.
Milling cups, including those with bonded ceramic inserts,
can be cleaned with alcohol or petrol, or can also be boiled
out briefly.
Do not subject milling cups with ceramic inserts to sudden
temperature variations during rinsing.
The ceramic inserts can crack through sudden
temperature differences.
Drying the milling cups
The milling cups can be dried in a drying oven, at any time
after cleaning, at the temperatures given below.
Milling cup material
Temperature
Special steel
Up to 200°C
Stainless steel
Up to 200°C
Tungsten carbide
Up to 50°C
Agate
Up to 120°C
Zirconium oxide
Up to 120°C

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Operation via the display unit of the RS200
The mill has a new, very comfortable operator control system.
All relevant data can be entered or called via a graphic display
with one knob operation.
The menu system is multilingual.
Name
Function
A
Display
Displays the menu, parameter settings, operating instructions and fault
signalling.
B
START button
Starts the milling process
C
STOP button
Stops the milling process
D
Button
Opens the milling chamber hood
E
Setting knob
By turning and pressing, all menu points can be selected and parameters set.
Turning 1
By turning, the various menu points can be selected. Selected menu points
are displayed inversely.
Turning 2
Setting of parameters in the opened menu points (see Pressing 1)
Pressing 1
Selected menu points are opened
Pressing 2
Short pressing confirms setting of parameters
Pressing 3
Continuous pressing: jump back to the 1st menu level
Symbols in the display unit
Programme mode –Take over parameters
Programme mode –Change programme
Programme mode –Delete programme
Warning sound off
Service due
Motor or frequency converter too hot
A
b
b
.
1
A
b
b
.
2
°C
Fig. 15 Control panel
Abb.16 Bedienfeld
A
B
C
E
D