Retsch AT 100 XL User manual

© Retsch GmbH, 42781 Haan, Retsch-Allee 1-5, Germany 07.12.2016 0005
Manual
Abrasion Tester AT 100 XL
Translation

2
COPYRIGHT
© Copyright by
Retsch GmbH
Haan, Retsch-Allee 1-5
D-42781 Haan
Federal Republic of Germany

3
1Notes on the Operating Manual................................................................5
1.1 Explanations of the safety warnings ...........................................................6
1.2 General safety instructions........................................................................7
1.3 Repairs...................................................................................................8
2Confirmation............................................................................................9
3Transport, scope of delivery, installation.................................................9
3.1 Packaging ...............................................................................................9
3.2 Transport..............................................................................................10
3.3 Temperature fluctuations and condensed water .........................................10
3.4 Conditions for the place of installation ......................................................10
3.5 Installation of the machine......................................................................10
3.6 Type plate description ............................................................................11
3.7 Electrical connection...............................................................................12
3.8 Transport..............................................................................................12
3.9 Installation of the machine......................................................................13
4Technical data .......................................................................................14
4.1 Use of the machine for the intended purpose.............................................14
4.2 Volume and feed size .............................................................................15
4.3 Rated power..........................................................................................15
4.4 Motor rotation speed ..............................................................................15
4.5 Emissions .............................................................................................16
4.5.1 Noise levels AT 100 XL: ...................................................................16
4.6 Degree of protection ..............................................................................16
4.7 Protective equipment .............................................................................16
4.8 Dimensions and weight...........................................................................16
4.9 Required floor space...............................................................................16
5Operating the machine ..........................................................................17
5.1 Views of the Instrument .........................................................................17
5.2 Overview table of the parts of the device ..................................................18
5.3 Operating elements and displays .............................................................18
5.4 Overview Table of the Operating Elements and the Display ......................... 19
5.5 Opening the device ................................................................................19
5.6 Closing the device..................................................................................19
5.7 Emergency unlocking .............................................................................19
5.8 Inserting the testing media .....................................................................21
5.9 Preparing the testing process ..................................................................22
5.9.1 Weighing the paddle ........................................................................22
5.9.2 Filling of Material.............................................................................22
5.9.3 Close testing chamber .....................................................................23
5.9.4 Starting the process ........................................................................23
5.10 Accessories .......................................................................................24
5.11 Display unit –operation of the device ...................................................24
6Lubrication, Service and returning for maintenance ..............................25
6.1 Lubrication............................................................................................25
6.2 Service.................................................................................................26

4
6.3 Returning for service and maintenance.....................................................26
7Disposal.................................................................................................27
8Index .....................................................................................................28
Appendix ...................................................................................following page

Notes on the Operating Manual
5
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1 Notes on the Operating Manual
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This operating manual is a technical guide on how to operate the device safely and
it contains all the information required for the areas specified in the table of contents.
This technical documentation is a reference and instruction manual. The individual
chapters are complete in themselves.
Familiarity (of the respective target groups defined according to area) with the
relevant chapters is a precondition for the safe and appropriate use of the device.
This operating manual does not contain any repair instructions. If faults arise or
repairs are necessary, please contact your supplier or get in touch with Retsch
GmbH directly.
Application technology information relating to samples to be processed is not
included but can be read on the Internet on the respective device’s page at
www.retsch.com.
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Changes
Subject to technical changes.
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Copyright
Disclosure or reproduction of this documentation, use and disclosure of its contents
are only permitted with the express permission of Retsch GmbH.
Infringements will result in damage compensation liability.
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Notes on the Operating Manual
6
1.1 Explanations of the safety warnings
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In this Operating Manual we give you the following safety warnings
Serious injury may result from failing to heed these safety warnings. We give you
the following warnings and corresponding content.
WARNING
Type of danger / personal injury
Source of danger
–Possible consequences if the dangers are not observed.
•Instructions on how the dangers are to be avoided.
We also use the following signal word box in the text or in the instructions on action
to be taken:
WARNING
Moderate or mild injury may result from failing to heed these safety warnings. We
give you the following warnings and corresponding content.
CAUTION
Type of danger / personal injury
Source of danger
–Possible consequences if the dangers are not observed.
•Instructions on how the dangers are to be avoided.
We also use the following signal word box in the text or in the instructions on action
to be taken:
CAUTION
In the event of possible property damage we inform you with the word “Instructions”
and the corresponding content.
NOTICE
Nature of the property damage
Source of property damage
–Possible consequences if the instructions are not observed.
•Instructions on how the dangers are to be avoided.
We also use the following signal word in the text or in the instructions on action to
be taken:
NOTICE
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Notes on the Operating Manual
7
1.2 General safety instructions
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CAUTION
Read the Operating Manual
Non-observance of these operating instructions
–The non-observance of these operating instructions can
result in personal injuries.
•Read the operating manual before using the device.
•We use the adjacent symbol to draw attention to the
necessity of knowing the contents of this operating
manual.
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Target group : All persons concerned with the machine in any form
This machine is a modern, high performance product from Retsch GmbH and
complies with the state of the art. Operational safety is given if the machine is
handled for the intended purpose and attention is given to this technical
documentation.
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You, as the owner/managing operator of the machine, must ensure that the people
entrusted with working on the machine:
•have noted and understood all the regulations regarding safety,
•are familiar before starting work with all the operating instructions and
specifications for the target group relevant for them,
•have easy access always to the technical documentation for this machine,
•and that new personnel before starting work on the machine are familiarised
with the safe handling of the machine and its use for its intended purpose,
either by verbal instructions from a competent person and/or by means of this
technical documentation.
Improper operation can result in personal injuries and material damage. You are
responsible for your own safety and that of your employees.
Make sure that no unauthorised person has access to the machine.
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CAUTION
Changes to the machine
–Changes to the machine may lead to personal injury.
•Do not make any change to the machine and use spare parts and
accessories that have been approved by Retsch exclusively.
NOTICE
Changes to the machine
–The conformity declared by Retsch with the European Directives will lose
its validity.
–You lose all warranty claims.
•Do not make any change to the machine and use spare parts and
accessories that have been approved by Retsch exclusively.
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Notes on the Operating Manual
8
1.3 Repairs
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This operating manual does not contain any repair instructions. For your own safety,
repairs may only be carried out by Retsch GmbH or an authorized representative or
by Retsch service engineers.
In that case please inform:
The Retsch representative in your country
Your supplier
Retsch GmbH directly
Your Service Address:
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Confirmation
9
2 Confirmation
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This operating manual contains essential instructions for operating and maintaining
the device which must be strictly observed. It is essential that they be read by the
operator and by the qualified staff responsible for the device before the device is
commissioned. This operating 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 (s)he has received sufficient instructions about the operation and
maintenance of the system. The user has received the operating 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.
As the owner/managing operator you should for your own protection have
your employees confirm that they have received the instructions about the
operation of the machine.
I have read and taken note of the contents of all chapters
in this operating manual as well as all safety instructions
and warnings.
User
Surname, first name (block letters)
Position in the company
Signature
Service technician or operator
Surname, first name (block letters)
Position in the company
Place, date and signature
3 Transport, scope of delivery, installation
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3.1 Packaging
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The packaging has been adapted to the mode of transport. It complies with the
generally applicable packaging guidelines.

Transport, scope of delivery, installation
10
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NOTICE
Storage of packaging
–In the event of a complaint or return, your warranty claims may be
endangered if the packaging is inadequate or the machine has not been
secured correctly.
•Please keep the packaging for the duration of the warranty period.
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3.2 Transport
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NOTICE
Transport
–Mechanical or electronic components may be damaged.
•The machine may not be knocked, shaken or thrown during
transport.
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NOTICE
Claim
–In case of any transport damage, you must inform the forwarder and also
Retsch GmbH immediately. Claims that are made later, may not be
considered.
•Inform the forwarder and Retsch GmbH within 24h.
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3.3 Temperature fluctuations and condensed water
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NOTICE
Temperature fluctuations
The machine may be subject to strong temperature fluctuations during transport
(e.g. aircraft transport)
–The resultant condensed water may damage electronic components.
•Protect the machine from condensed water.
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3.4 Conditions for the place of installation
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Ambient temperature: 5 °C to 40 °C
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NOTICE
Ambient temperature
–Electronic and mechanical components may be damaged and the
performance data alter to an unknown extent.
•Do not exceed or fall below the permitted temperature range of the
machine (5 °C to 40 °C / ambient temperature).
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3.5 Installation of the machine
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Installation height: maximum 2000 m above sea level

Transport, scope of delivery, installation
11
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3.6 Type plate description
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Fig. 1: Type plate lettering
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
9 Power version
10 Mains frequency
11 Capacity
12 Amperage
13 Number of fuses
14 Fuse type and fuse strength
In the case of questions please provide the device designation (1) or the part
number (3) and the serial number (4) of the device.
1
2
3
4
5
6
7
8
9
1
0
1
1
1
2
1
4
1
3

Transport, scope of delivery, installation
12
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3.7 Electrical connection
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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.
•Please check the type plate for details on the necessary voltage and
frequency for the device.
•Make sure the levels agree with the existing mains power supply.
•Use the supplied connection cable to connect the device to the mains power
supply.
Pos: 5.2 /0005 RETSCH/0005 RETSCH Bedienungsanleitungen Kapitelsammlungen/RS 300 XL/15 Transport
Lieferumfang und Aufstellen/1504 Modul Wichtige Hinweise zum elektrischen Anschluss RS 300 XL / PM400
@ 7\mod_1390222856178_9.docx @ 54780 @ @ 1
•Make sure that the voltage and frequency of your mains connection
corresponds to that on the type plate of the AT 100 XL.
–The mains connection must be fused to at least 15A
–An electrical connection without protective earth PE is not permitted.
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3.8 Transport
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WARNING
Serious personal injury
Falling loads
–The appliance is very heavy and can therefore cause serious personal
injuries if it falls down.
•Lifting above head height is not permissible!
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NOTICE
Transport safeguard
–Components may be damaged.
•Operate the machine only without the transport safeguard or
transport the machine only with transport safeguard.
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Transport, scope of delivery, installation
13
Fig. 2: Dismounting the transport screws
The device should only be lifted and transported using the 4 supplied transport
screws (TS).
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NOTICE
Transport
–Mechanical or electronic components may be damaged.
•The machine may not be knocked, shaken or thrown during
transport.
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3.9 Installation of the machine
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•Place the device on a firm surface.
Please refer to the “Technical Data” chapter for further parameters.
The device must be locked before it is put into operation.
TS

Technical data
14
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4 Technical data
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4.1 Use of the machine for the intended purpose
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CAUTION
1.V0004
Risk of explosion or fire
Changing sample properties
–Consider that the properties and therefore also the hazardousness of your
sample can change during the grinding process.
•Do not use any substances in this device which carry the risk of
explosion or fire.
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CAUTION
Risk of explosion or fire
–On account of its design, the device is not suitable for use in hazardous
(potentially explosive) atmospheres.
•Do not operate the device in a hazardous atmosphere.
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CAUTION
Danger of personal injury
Dangerous nature of the sample
–Depending on the dangerous nature of your sample, take the
necessary measures to rule out any danger to persons.
•Observe the safety guidelines and datasheets of your
sample material.
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Target group: Operator, All persons concerned with the machine in any form.
Machine type designation: AT 100 XL
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Technische Daten RS 300 XL/1010 Modul Einsatz bei bestimmungsgemäßer Verwendung RS 300 XL @
7\mod_1389859724281_9.docx @ 54540 @ @ 1
A detailed overview and knowledge of the characteristics of a raw material is of
utmost importance, especially when planning the layout of a crushing plant. In
order to minimize all possible risks extensive trials are necessary to obtain
information on the properties of the raw materials. A clear definition of the required
crushing capacities and the desired product quality can be precisely determined by
using the Bond Index test methods. Using the Bond Index test procedures it is
possible to calculate crushing / abrasion behavior of mineral samples. This
knowledge is essential to define the required ball mill layout and production
capacity.

Technical data
15
Advantages
–suitable for the determination of Work Index according to Bond
–fixed parameters according to Bond Index standards
–removable ringsieve
–solid steel frame
–removable sample collector
–chamber with gasket for loss-free operation
–solid noise-protection hood with safety switch
–emergency switch
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NOTICE
Area of use of the machine
–This machine is a laboratory machine designed for 8-hour single-shift
operation.
•This machine may not be used as a production machine nor is it
intended for continuous operation.
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4.2 Volume and feed size
According to the Bond Index standard 4 times 400 grams of material with a feed size
between 12 and 19mm are required.
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4.3 Rated power
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0.55 KW
Make sure that the voltage and frequency of your mains connection corresponds to
that on the type plate of the device. The mains connection must be fused to at least
15A.
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NOTE
Reduction of tool service life
Abrasive sample materials
–The presence of abrasive composite materials during grinding can
considerably reduce tool service life.
•When grinding electronic scrap, take the properties of the composite
materials into account.
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4.4 Motor rotation speed
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The speed is fixed at 70rpm for the chamber and 632rpm for the paddle.
Those parameters are according to the Bond Index standards.

Technical data
16
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4.5 Emissions
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CAUTION
Possibility of acoustic signals not being heard
Loud grinding noises
-Acoustic alarms and voice communication might not be heard.
•Consider the volume of the grinding noise in relation to other
acoustic signals in the work environment. You may wish to use
additional visual signals.
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4.5.1 Noise levels AT 100 XL:
Noise measurement in accordance with DIN 45635-31-01-KL3
The noise levels are largely influenced by the machine speed, the grinding material
and the grinding set.
Workplace-related emissions value LpAeq = up to 76dB (A)
Sound power level LWA = 89dB (A)
Measurement conditions:
Sample material: 400g cement clinker, particle size 12-19mm
Sound level meter: Brüel & Kjaer 2237 Controller
Pos: 6.22 /0020 Übersc hriften/1.1 Übersc hriften/1.1 Überschrifte n BDA/11 Schutzart @ 0\ mod_122649 1839164_9.doc x@ 33 28@ 2@ 1
4.6 Degree of protection
Pos: 6.23 /0005 RETSCH/ 0005 RETSCH Be dienungsanleitunge n Kapitelsammlung en/RS 300 XL/1 0T echnische Daten RS 3 00X L/1040 Modul Schutz artR S 300 XL @ 7\mod_138 9861008159_9.d ocx @ 54623 @ @ 1
IP 55
Pos: 6.24 /0020 Übersc hriften/1.1 Übersc hriften/1.1 Überschrif ten BDA/11 Schutzei nrichtungen @ 0\ mod_1226486316 130_9.docx @ 3304 @ 2 @ 1
4.7 Protective equipment
Pos: 6.25 /0005 RETSCH/ 0005 RETSCH Be dienungsanleitunge n Kapitelsammlung en/RS 300 XL/1 0T echnische Daten RS 3 00X L/1045 Modul Schutz einrichtung RS 300 XL @ 7\ mod_138986102 8669_9.docx @ 546 35@ @ 1
The device is equipped with automatic lid closing which prevents it being started in
an unsafe state.
–The device can only be started with closed cover.
–The cover can only be opened when the device has come to a halt.
Pos: 6.26 /0020 Übersc hriften/1.1 Übersc hriften/1.1 Überschrifte n BDA/11 Abmessu ngenu ndG ewicht Retsch @ 0\ mod_122649 2212173_9.doc x@ 3 352 @ 2 @ 1
4.8 Dimensions and weight
Pos: 6.27 /0005 RETSCH/ 0005 RETSCH Be dienungsanleitunge n Kapitelsammlung en/RS 300 XL/1 0T echnische Daten RS 3 00X L/1055 Modul Abm essungen und Gewicht R S 300 XL @ 7\mod_138986 3251128_9.doc x@ 5 4662 @ @ 1
Height: 1240mm / Width: 720mm / Depth: 910mm
Weight: AT 100 XL net approx. 260kg
Pos: 6.28 /0020 Übersc hriften/1.1 Übersc hriften/1.1 Überschrifte n BDA/11 Erforderlic heS tandfläche @ 0\ mod_1226492678 414_9.docx @ 3364 @ 2 @ 1
4.9 Required floor space
Pos: 6.29 /0005 RETSCH/ 0005 RETSCH Be dienungsanleitunge n Kapitelsammlung en/RS 300 XL/1 0T echnische Daten RS 3 00X L/1060 Modul Stan dflächeR S 300 XL @ 7\mod_1 38986325260 8_9.docx @ 54674 @ @ 1
Height: 1800mm (open cover): / Width: 720mm / Depth: 910mm

Operating the machine
17
:7 .1 /0020 Überschrift en/1.Ü berschriften/1 B edienung des Gerätes @ 0\ mod_122656 5880211_9.docx @ 35 19 @ 1 @ 1
5 Operating the machine
Pos: 7.2 /0020 Überschrift en/1.1 Überschrift en/1.1 Überschrift enBD A/11 Ansichten des Ger ätesR etsch @ 0\ mod_1228990581 782_9.docx @ 4966 @ 2 @ 1
5.1 Views of the Instrument
Pos: 7.3 /0005 RETSCH /0005 RETSCH Be dienungsanleitung en Kapitelsammlu ngen/RS 300 XL/20 Bedi enungR S 300 XL/200 0Mo dul Ansichten des G erätes @ 8\mod_141 7604869773_9.doc x@ 6 9058 @ @ 1
Fig. 3: Front view of the device
Pos: 7.4 /0005 RETSCH /0005 RETSCH Bedie nungsanleitung enK apitelsammlunge n/-------Seitenu mbruch ----------- @ 0\mod_1222344373 758_0.docx @ 2386 @ @ 1
A
B
C
D
E
F

Operating the machine
18
Pos: 7.5 /0020 Überschrift en/1.1 Überschrift en/1.1 Überschri ften BDA/11 Übersichtst abelle der Gerätet eile @ 0\mod_12289 90616846_9.docx @ 4 972 @ 2@ 1
5.2 Overview table of the parts of the device
Pos: 7.6 /0005 RETSCH /0005 RETSCH Bedie nungsanleitung en Kapitelsam mlungen/RS 300 XL/20 Bedi enungR S 300 XL/200 3Mo dul Übersichtstabell e der Geräteteile @ 8\m od_14177858100 19_9.docx @ 69100 @ @ 1
Element
Description
Function
A
Hood
Closes the grinding chamber
B
Emergency Stop-Button
After pressing this button, the machine will
immediately stop working
C
Control panel
Device controller
D
Main switch
Button for switching machine to On-/Off
E
Chamber
Chamber for the testing process
F
Collecting pan (optional)
Collects the material after opening the
chamber
Pos: 7.7 /0020 Überschrift en/1.1 Überschrift en/1.1 Überschrift enBD A/11 Ansichten der Be dienelemente und der Anz eige @ 0\mod_ 1226566362336 _9.docx @ 3537 @ 2 @ 1
5.3 Operating elements and displays
Pos: 7.8 /0005 RETSCH /0005 RETSCH Bedie nungsanleitung enK apitelsammlunge n/RS 300 XL/20 Bedi enungR S 300 XL/200 1Mo dul Ansichten der Bedie nelemente und der Anzeig e @ 8\mod_1 417604958128_9.do cx @6 9070 @ @ 1
Fig. 4: View of the control panel
M
N
L

Operating the machine
19
.9 /0020Ü berschriften/ 1.1Ü berschriften/ 1.1Ü berschriften BDA/ 11Ü bersichtstabell e der Bedienelement e und der Anzeige @ 0\ mod_1228990697 273_9.docx @ 4978 @ 2 @ 1
5.4 Overview Table of the Operating Elements and the Display
Pos: 7.10 /0005 RETSCH/ 0005 RETSCH Be dienungsanleitunge n Kapitelsammlung en/RS 300 XL/2 0Be dienung RS 300 XL/20 02M odul Übersichtst abelle der Bedienelem ente und der Anzeige @ 8\m od_141778575 5940_9.docx @ 69088 @ @ 1
Element
Description
Function
L
Operating button
control to operate the device settings
M
Button to open the hood
Unlocks the hood
N
Display
Displays the control functions and
parameters
os: 7.11 /0020 Überschrift en/1.1 Überschrift en/1.1 Überschrift enBD A/11 Öffnen des Gerä tes@ 1\mod_124151 0397227_9.doc x@ 88 12 @ 2 @ 1
5.5 Opening the device
Pos: 7.12 /0005 RETSCH/ 0005 RETSCH Be dienungsanleitunge n Kapitelsammlung en/RS 300 XL/2 0Be dienung RS 300 XL/20 05M odul Öffnen des Gerätes RS 300 XL / PM400 @ 7\mod_ 1390224848766_ 9.docx @ 54802 @ @ 1
The following steps are necessary in order to be able to use and clamp the grinding
jar.
•Connect the device to the mains.
•Switch on the main switch at the right site of the device.
•Press the button F3 (open lid).
The safety lock opens and the lid can be lifted up
Pos: 7.13 /0020 Übersc hriften/1.1 Übersc hriften/1.1 Überschrif ten BDA/11 Schließ end es Gerätes @ 7\mod _1390224720831 _9.docx @ 54791 @ 2 @ 1
5.6 Closing the device
Pos: 7.14 /0005 RETSCH/ 0005 RETSCH Be dienungsanleitunge n Kapitelsammlung en/RS 300 XL/2 0Be dienung RS 300 XL/20 10M odul Schließen des G erätes RS 300 XL / PM400 @ 7\ mod_139022488 4117_9.docx @ 5481 4 @ @ 1
It is only possible to lock the grinding chamber if the device has been connected to
the power supply and the main switch at the right site of the device has been
switched on.
•Shut the housing lid.
–A sensor detects the closing pin of the housing lid
–Press the button F3 (close lid).
5.7 Emergency unlocking
Pos: 7.16 /0025 Warnhinweise/ V0009 VORSICHT Notentr iegelung @ 1\mod_12416 12025489_9.docx @ 9471 @ @ 1
CAUTION
Emergency Unlocking
Drive continuing to run
–There is a substantial risk of injury if the drive and associated device parts
run on a long time without being braked!
•Activate the emergency unlocking only when the machine has come
to a complete stop and is disconnected from the power supply.

Operating the machine
20
Pos: 7.17 /0005 RETSCH/ 0005 RETSCH Be dienungsanleitunge n Kapitelsammlung en/RS200/20 Bedie nungR S200/201 5Mod ulN otentriegelung @ 7\mod_1390224 887547_9.doc x@ 548 26 @ @ 1
Fig. 5: Opening for emergency release
A key is provided with device delivery. This can be used to open the device
manually in the case of a power failure .
•Remove the cap (AK).
•Place the key in the device (NR).
Fig. 6: Emergency release procedure
•Rotate it in anti-clockwise direction as far as it will go.
–The lock is open and the lid can be lifted up.
–To start the machine, the device must be locked again.
NR
AK
NR