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Retsch Emax Manual

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

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  • Page 1 Manual High Energy Ball Mill Emax Translation © Retsch GmbH, 42781 Haan, Retsch-Allee 1-5, Germany | 20.01.2020 Version 0009...
  • Page 2 Copyright © Copyright by Retsch GmbH Retsch-Allee 1-5 42781 Haan Germany...

  • Page 3: Table Of Contents

    Table of Contents Notes on the manual ..........................7 Explanation of signs and symbols ..................... 7 Disclaimer ............................7 Copyright............................7 Safety ..............................8 Explanations of the Safety Instructions ..................... 9 General Safety Instructions ......................10 Repairs ............................. 11 Confirmation Form for the Managing Operator................12 Technical Data .............................
  • Page 4 6.8.2 Opening ............................39 6.8.3 Grinding Jar Identification ......................39 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 ................
  • Page 5 Error Messages and Information Notes .................... 61 Error Messages ..........................61 Information Notes ..........................62 Return for Service and Maintenance ....................63 Cleaning, Wear and Maintenance ...................... 64 Cleaning ............................64 9.1.1 Cleaning of the Grinding jar ......................64 9.1.2 Drying the Grinding Jars ......................
  • Page 6 Notes on the manual...

  • Page 7: Notes On The Manual

    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.

  • Page 8: Safety

    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.

  • Page 9: Explanations Of The Safety Instructions

    Safety 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”...

  • Page 10: General Safety Instructions

    − 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.

  • Page 11: Repairs

    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...

  • Page 12: Confirmation Form For The Managing Operator

    Safety 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.

  • Page 13: Technical Data

    Technical Data 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. −...

  • Page 14: Electromagnetic Compatibility (Emc)

    Technical Data Example 2: Container: 2 zirconium grinding jars (125 ml) Grinding body: 275 g ZrO balls 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 = 76 dB(A).

  • Page 15: Feed Grain Size

    Technical Data − 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"...

  • Page 16: Packaging, Transport And Installation

    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.
  • Page 17 Packaging, Transport and Installation 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.

  • Page 18: Electrical Connection

    Packaging, Transport and Installation 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. •...

  • Page 19: Removing The Transportation Lock

    Packaging, Transport and Installation 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.
  • Page 20 Packaging, Transport and Installation 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.

  • Page 21: Removing The Transportation Aid

    Packaging, Transport and Installation Fig. 5: Free-force compensation sockets: do not push or pull the device NOTICE N10.0071 Damage to the free-force compensation sockets Pushing or pulling the device − The free-force compensation sockets will be damaged if the device is pulled or pushed across a surface.
  • Page 22 Packaging, Transport and Installation The two transportation aids (TH) are fixed by four screws (TS) to the underside of the device.  Use a 13 mm open-end wrench to remove the screws.

  • Page 23: First Commissioning

    First Commissioning First Commissioning WARNING W4.0002 Danger to life through electric shock Damaged power cable − Operating the device with a damaged power cable or plug can lead to life- threatening injuries caused by an electric shock. • Before operating the device, check the power cable and plug for damage.
  • Page 24 First Commissioning NOTICE The coolant consists of cooling liquid and a coolant additive. Only clean, lime-free water is permitted as cooling liquid. The coolant additive (article no. 02.362.0027) is included with the delivery of the device and can be ordered separately when required. ...
  • Page 25 First Commissioning Fig. 8: Deaerating the system  To deaerate the system, insert the supplied syringe with depressed plunger into the suction opening (AS) in the bottom of the coolant tank and then withdraw the plunger of the syringe completely. ...

  • Page 26: Connection To An External Cooler

    First Commissioning Maximum coolant volume ~ 600 ml Fig. 9: Maximum and minimum fill level  Check the supply of coolant regularly. The coolant level must be within the maximum and minimum fill levels. The minimum fill level is defined by the coolant feed inside the tank. ...

  • Page 27: Cooling Surfaces Of The Grinding Jar

    First Commissioning Fig. 10: Connections for external cooling Two 10/8 mm hoses (not contained in the scope of delivery) can be connected to the connections already mounted on the housing. Alternatively, the connections can be removed and replaced by own screw connections with a G 1/4'' thread. NOTICE Please check the tightness of both connections.
  • Page 28 First Commissioning Fig. 11: Cooling surfaces of the grinding jar support Fig. 12: Cooling surfaces of the grinding jar NOTICE As a result of the operation, corrosion may occur at the contact surfaces of the grinding jars and grinding jar supports. This is normal and harmless.

  • Page 29: Operating The Device

    • Take note of the safety data sheets for the sample material. This High Energy Ball Mill of the Retsch GmbH is a laboratory device. It grinds and mixes soft, medium-hard to extremely hard, brittle and fibrous materials. Minerals, ores, alloys, chemicals, glass, ceramics, plant parts, soil, sewage sludge and many other substances can be ground easily, quickly and without loss.

  • Page 30: Principle Of Operation

    Operating the Device The High Energy Ball Mill of the Retsch GmbH is successfully deployed in almost all areas of industry and research, especially where there are high demands regarding cleanliness, speed, fineness and reproducibility. Only grinding sets from Retsch GmbH may be used. Dry and wet grinding may be conducted.
  • Page 31 Operating the Device Fig. 13: Front view of the device Element Description Function Locking mechanism Keeps the device closed Operating controls (touchscreen) Operation of the device Turning handle of the grinding jar Clamps the grinding jar support Turning handle locking pin Secures the turning handle of the grinding jar support Grinding jar...

  • Page 32: Back

    Operating the Device Hood Closes the device 6.3.2 Back external cooling access max. 6 bar lowest temperature 5°C Fig. 14: Back view of the device Element Description Function Mains switch Switches the device on and off, disconnects the device from the mains RJ45 interface (Ethernet) Data connection (inactive) USB interface...

  • Page 33: Switching On / Off

    100 – 240 V) 6.4 Switching On / Off  Turn on the Emax with the mains switch (I) on the back side of the device. When the device is switched off, it is completely disconnected from the mains.

  • Page 34: Emergency Unlocking

    Operating the Device 6.6 Emergency Unlocking CAUTION C11.0009 Risk of injuries Drive coasting − In the event of a power failure, the drive on the device continues to coast for a long time, as does the drive on connected device parts. After activating the emergency release, items of clothing and parts of the body can get caught in moving components of the device.

  • Page 35: Opening And Closing The Grinding Jar Support

    Operating the Device Fig. 16: Activating the emergency unlocking 6.7 Opening and Closing the Grinding Jar Support CAUTION C12.0024 Risks of burns and scalding Hot grinding jar and/or sample material − The sample material and grinding jar can get very hot during the grinding process.

  • Page 36: Closing

    Removing the grinding jar 6.7.2 Closing With the Emax a very large amount of energy enters the sample material.  Therefore, make sure that the grinding jar support has been closed properly.  Before grinding check the lock on the grinding jar support (VR).
  • Page 37 Operating the Device Fig. 19: Locking the grinding jar support The turning handle (C) of the grinding jar support (G) is secured by the locking pin (D) to prevent inadvertent opening.  Turn the locking pin (D) until it engages in the groove (DN). ...

  • Page 38: Opening And Closing The Grinding Jar

    Fig. 23: Closing the grinding jar With the Emax a very large amount of energy enters the sample material.  Therefore ensure the careful closing of the grinding jar.  When closing the grinding jar, ensure that the sealing gasket (DM) is firmly in place.

  • Page 39: Opening

    6.9 Ball Sizes and Speeds With the Emax a very large amount of energy enters the sample material. This high amount of energy also acts on the grinding jar and the grinding balls. Therefore, depending on the jar size the following recommendations for the sample amount and the ball sizes used apply.

  • Page 40: Recommended Grinding Jar Filling

    In addition to the instrument settings, the filling level of the grinding jar is also of crucial importance for a successful grinding process in the High Energy Ball Mill of Retsch GmbH. When grinding bulk materials, the grinding jar filling should consist of approximately one third of sample and one third of ball quantity.
  • Page 41 Correct mounting of the grinding places NOTICE Both grinding places must always be loaded. If only one grinding jar is needed, the second grinding jar must be inserted empty (no grinding balls, no sample material) as counterbalance. Never operate the Emax without grinding jars!

  • Page 42: Wet Grinding With Highly Flammable Materials

    Operating the Device Fig. 26: Inserting the grinding jar 6.11 Wet Grinding with Highly Flammable Materials Wet grinding using highly flammable materials is permitted with this device if certain precautionary measures are complied with. When using highly flammable materials such as hexane, isopropyl, ethanol, benzine etc. as a grinding aid , the inside of the grinding jars should be classed as Zone 0, i.e.

  • Page 43: Controlling The Device

    Controlling the Device Controlling the Device 7.1 Operating Controls, Displays and Functions Fig. 27: Control panel areas Element Description Function Navigation Selection of the operating modes "Manual", "Program" and "Sequence". Display of date and time. Access to the menu "Settings" Settings and display of Settings of grinding parameters and display of parameters...
  • Page 44 Controlling the Device B1.1 22.04.2014 PROGRAM B1.3 14:23 B1.2 B2.2 B2.1 B2.4 Temperature 65°C 70°C B2.3 B2.6 50°C Process time 01:00:00 B2.5 Speed 1800 B2.7 B2.8 Interval Interval time B2.9 00:15:00 B2.10 Pause time 00:05:00 B2.11 Direction reversal B3.1 B3.2 Fig.

  • Page 45: Operating Modes And Navigation

    Controlling the Device B2.5 Process time Displays the grinding duration B2.6 Temperature, temperature Displays the current grinding jar temperature limits (outside) and the set temperature limits B2.7 Speed Display of the speed and rotation direction B2.8 Interval Indicates whether the interval grinding is active or inactive B2.9 Interval time...
  • Page 46 Controlling the Device − Process time − Speed − Interval time − Pause time In manual mode the parameters can be edited directly. In programme mode the parameters can only be changed when the edit mode has been activated via the icon (B2.2).

  • Page 47: Activatable Or Deactivatable Parameters

    Controlling the Device Pause time: The pause time defines the duration of the grinding pause between two intervals. An arbitrary pause time between 00:01:00 and 99:59:59 (hh:mm:ss) can be set in the data entry window. The process time keeps running parallel to the pause time. ...

  • Page 48: Stop Process

    Controlling the Device After the start of the grinding the cooling (B2.3) is activated. The flow icon changes from (inactive) to (active). The buttons appear now in the control panel area of the device control (B3).  During the grinding process, it is not possible to access the menu "Settings" (the button (B1.3) is inactive).

  • Page 49: Select A Programme

    Controlling the Device − Pause time − Speed − Interval − Direction reversal Please refer to Chapter "Grinding Parameters" for a detailed description of the parameter settings. Furthermore, an individual heading and description can be assigned to each programme. 7.5.1 Select a Programme 22.04.2014 PROGRAM 14:23...

  • Page 50: Edit A Programme

    Controlling the Device  Press the button (B4.3) to cancel the editing without saving the description and heading. The entries are not applied, and the menu displays the previous screen (programme description).  Press the button (B4.5) to save the description and heading. The description and heading are applied, and the menu display the previous screen (programme description).

  • Page 51: Sequence Mode

    Controlling the Device  Press the button to save the values. Entered values are applied, and the menu displays the previous screen. 7.6 Sequence Mode For special grinding tasks, previously saved programmes can be combined to one sequence in this mode. This allows for the design of very complex grinding processes. There are three sequence memory positions available.

  • Page 52: Select A Sequence

    Controlling the Device 7.6.1 Select a Sequence  Press the sequence name button (B5.4). The sequence selection window opens. The current sequence is displayed in grey in the list.  To open the sequence description of the respective sequence, press the icon.

  • Page 53: Delete A Programm From A Sequence

    Controlling the Device 7.6.3.3 Delete a Programm from a Sequence  Press the arrow  of the memory line containing the programme to be deleted. The list of all saved programmes appears.  Press on the top line "- (no program)". The programme is removed from the sequence and the menu displays the previous screen.
  • Page 54 Controlling the Device 22.04.2014 Settings 14:23 Languages Date and time Signal tone ✓ Automatic opening ✓ Extended time 10 min Temperature limits Timer settings Copy logbook Cleaning mode ✓ Operating hours Software versions User information Service environment Fig. 35: Menu "Settings" The following settings can be accessed via the menu: −...

  • Page 55: Languages

    Controlling the Device The individual functions are described in detail in the following subchapters.  Press the button to return to exit the "Settings" menu. 7.7.1 Languages In this menu the language of the control panel can be selected.  Press on the desired language. After the selection, the entire menu structure is displayed in the selected language.

  • Page 56: Temperature Limits

    Controlling the Device The currently set time is displayed in small letters below the extended time button. 7.7.6 Temperature Limits This function allows to implement additional grinding pauses for temperature-sensitive sample materials when a certain temperature limit is exceeded. The cooling phase can thus prevent an overheating of the sample material.

  • Page 57: Grinding With Activated Temperature Limits

    Controlling the Device  Press the speed button to activate or deactivate the function. The activated function is marked with the icon and the speed will be reduced to 300 rpm upon reaching the set maximum temperature. When the function is deactivated, the drive will stop completely when the set maximum temperature is reached.

  • Page 58: Timer Settings

    Controlling the Device Fig. 38: Warning note: hot grinding jars If the grinding jar temperature exceeds 130 °C, the grinding process is aborted for safety reasons.  Allow the device to cool down.  If not yet done, connect the external cooling. 7.7.7 Timer Settings 7.7.7.1 Setting the Timer...

  • Page 59: Copy Logbook

    With this menu function, the following information will be transferred in ASCII format (text format) to a connected USB stick: − List of error messages (sum counter) − Logbook (device log) of the Emax  Plug a suitable USB storage device into the USB port (K) on the back of the device. NOTICE USB 3.0 storage devices are not supported.

  • Page 60: Operating Hours

    The firmware and display software must be located in the root directory. The device then automatically recognises the new software. 7.7.12 User Information  The user information is currently disabled. 7.7.13 Service Environment The service environment is password protected and can only be accessed by service technicians from Retsch GmbH.

  • Page 61: Error Messages And Information Notes

    Error Messages and Information Notes Error Messages and Information Notes 8.1 Error Messages Error messages inform the user about detected device or programme errors. In the event of an error message, a fault has occurred, in which the operation of the device or the programme is automatically interrupted.

  • Page 62: Information Notes

    Error Messages and Information Notes  Switch off the main switch and wait for 30 s Failure in safety circuit before switching on again.  If the error persists, contact service.  Switch off the main switch and wait for 30 s Safety switch defective (locking) before switching on again.

  • Page 63: Return For Service And Maintenance

     When returning a device, attach the return form to the outside of the packaging. In order to eliminate any health risk to the service technicians, Retsch GmbH reserves the right to refuse the acceptance and to return the respective delivery at the expense of the sender.

  • Page 64: Cleaning, Wear And Maintenance

    Improper repairs − Unauthorised and improper repairs can cause injuries. • Repairs to the device may only be carried out by the Retsch GmbH , an authorised representative or by qualified service technicians. • Do not carry out any unauthorised or improper repairs to the device! 9.1 Cleaning...

  • Page 65: Drying The Grinding Jars

    • Run the device at least every 2-3 weeks (one cleaning cycle and 15 minutes at the lowest speed). • Replace the water with added coolant every 6 months. The maintenance of the Emax includes the regular exchange of the coolant. The coolant must be exchanged when it shows a significant cloudiness. 9.3.1 Exchange of the Coolant 9.3.1.1...
  • Page 66 Cleaning, Wear and Maintenance Fig. 40: Removing the lid (left), draining the coolant and rinsing the system (right)  Fill 600 ml of clean, lime-free water into the coolant tank. The water is circulated through the system and drained again via the hose. NOTICE Only use lukewarm water for rinsing.

  • Page 67: Filling New Coolant

    Cleaning, Wear and Maintenance  Clean the base (TB) of the coolant tank.  Also clean the previously removed filter insert (FE).  Reinsert the pipe (TR). Ensure the proper fit of the sealing gaskets. 9.3.1.2 Filling New Coolant NOTICE The coolant consists of cooling liquid and a coolant additive.

  • Page 68: Replacing The Fuses

    Cleaning, Wear and Maintenance ▪ No or too little coolant in the cooling system ▪ Flowmeter sensor faulty ▪ Pump faulty ▪ Blockage in the cooling system • Check whether sufficient coolant is in the coolant tank. 9.3.2 Replacing the Fuses WARNING W7.0014 Risk to life caused by an electric shock...

  • Page 69: Accessories

    Retsch GmbH homepage (http://www.retsch.com) under the heading "Downloads" of the device. Information on wear parts and small accessories can be found in the Retsch GmbH general catalogue also available on the homepage. In case of any questions concerning spare parts please contact the Retsch GmbH representative in your country, or Retsch GmbH directly.

  • Page 70: Cleaning The Aeration Lid

    After that the valves are thoroughly rinsed with water and dried. The cleaning with strong bases or acids is generally not recommended. Additional information concerning ultrasonic cleaning-baths can be found on the Retsch GmbH homepage (http://www.retsch.com).
  • Page 71 Accessories Risk of injury Cleaning with compressed air − When using compressed air for cleaning purposes dust and remnant of the sample material can be flung around and injure eyes. • Always wear safety glasses when cleaning with compressed air. •...

  • Page 72: Disposal

    Disposal 11 Disposal In the case of a disposal, the respective statutory requirements must be observed. In the following, information on the disposal of electrical and electronic devices in the European Community are given. Within the European Community the disposal of electrically operated devices is regulated by national provisions that are based on the EU Directive 2012/19/EU on Waste Electrical and Electronic Equipment (WEEE).

  • Page 73: Index

    12 Index Coolant feed ............26 Coolant tank ........15, 23, 24, 32 Accessories ............69 maximum fill level ........... 26 Activatable parameters ........47 minimum fill level ..........26 Additional cooling ..........15 removing the lid ..........66 cooling liquid ........... 15 removing the pipe ...........
  • Page 74 Fuse type ............19 Fuses ..............33 Edit window ............50 replacing ............68 Electrical connection ........... 18 Electromagnetic compatibility ......14 EMC ..............14 General catalogue ..........69 Emergency unlocking ......... 34 General safety instructions ........ 10 Emissions ............13 GrindControl Equivalent continuous sound level ....
  • Page 75 change ............45 manual ............45 Increase of sample volume during grinding programme ............. 45 process ............40 selection ............45 Inert atmosphere ..........69 sequence ............45 Inert gas .............. 69 Operating modes ..........45 Information note Operating the device .......... 29 H42 ............33, 48, 62 Organic solvents ..........
  • Page 76 Revolutions per minute ........40 maximum ............56 Rinsing the cooling system ......... 65 minimum ............56 RJ45 interface ............. 32 Temperature limits ..........56 Rotation direction .......... 45, 47 activated ............56 display ............57 Temperature range ..........17 Safety ..............
  • Page 77 Zirconium oxide ..........40, 65...
  • Page 79 Copyright © Copyright by Retsch GmbH Retsch-Allee 1-5 42781 Haan Germany...

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