Page 1 Table of Contents THREE ROLLER MILL Operating Instructions Article number: 27891EN Document number / Edition 27891EN-900-02 / Edition 02/2017 Translation of the original operating instructions, English 27891EN-900-02 / Edition 02/2017...
Page 3: Table Of Contents
Table of Contents TABLE OF CONTENTS Table of Contents Contact addresses 2.1. Manufacturer address 2.1.1. Imprint 2.2. Service and ordering spare parts Installation information in advance Safety 4.1. General information concerning safety 4.2. Safety symbols 4.3. Graphical conventions 4.4. Commissioning 4.5.
Page 4: Step
Table of Contents 6.10. IP protection 6.11. Roller temperature control 6.12. Rollers Unit description 7.1. Functional principle 7.2. Overview 7.2.1. Section view 7.3. Operating modes 7.3.1. Cleaning 7.3.2. Mixing 7.3.3. Gap-Gap 7.3.4. Gap-Force 7.3.5. Force-Force 7.4. Emergency stop 7.5. Safety devices 7.5.1.
Page 5: Cleaning Roller 2 And Roller
Table of Contents Transport 8.1. Packaging symbols 8.2. Intermediate storage 8.3. Uncrating 8.4. Instructions for lifting 8.4.1. Moving the machine by hand Installation 9.1. Setup site 9.2. Dismounting the load traverse 9.3. Mounting and aligning the operating unit 9.4. Connecting the electric supply 9.4.1.
Page 6 Table of Contents 10.15. Mounting hopper for working width 200 mm 10.16. Mounting splash guards for working width 200 mm 10.17. Mounting splash guards for inner side paneling 10.18. Mounting the solvent dispenser for guide lubrication Operating elements and operating unit 11.1.
Page 7 Table of Contents Maintenance 13.1. Cleaning the machine housing 13.1.1. Cleaning the display of the operating unit Maintenance and care 14.1. Service and maintenance plan Troubleshooting Shutting down 16.1. Short-term shutting down 16.2. Long-term shutting down 16.3. Putting out of operation Disposal 17.1.
Page 8: Contact Addresses
EXAKT Advanced Technologies GmbH Illustrations: EXAKT Advanced Technologies GmbH This documentation is copyrighted by EXAKT. Without prior written approval, the documentation may not be copied or be used contrary to the legitimate interests of EXAKT. Subject to change without notice! 2.2.
Page 9: Installation Information In Advance
Installation information in advance INSTALLATION INFORMATION IN ADVANCE The installation information in advance shall give you all information you need for preparing you site before the machine is delivered to you. It gives information how to handle and transport the machine, information for the setup site and electrical connection / preparation, etc.
Page 10: Safety
Safety SAFETY Link back to chapter 3 Installation information in advance 4.1. GENERAL INFORMATION CONCERNING SAFETY Every persons appointed to install, commission, operate, maintain and service the unit and the associate components must have read and understood these instructions and in particular the chapter Safety. If necessary, special training appropriate to the professional qualification of the persons in question shall be carried out.
Page 11: Safety Symbols
Safety 4.2. SAFETY SYMBOLS Symbol Meaning Warning of general and not categorized risks Warning of voltage Warning of rollers rotating reversely Danger of cuts Hot surface Suspended load Danger of hand injuries Danger of crushing Danger of tripping Warning of toxic substances Warnung of explosive substances Symbol Meaning...
Page 12: Graphical Conventions
Safety Wear protective apron / lab coat Disconnect machine from the mains Read operating instructions Reference to other documents 4.3. GRAPHICAL CONVENTIONS Symbol Meaning Tool This symbol indicates that a special tool or consumables are required.  Bulleted list Properties of the unit or individual components are listed in bulleted lists.
Page 13: Commissioning
Safety 4.4. COMMISSIONING The unit housing contains information signs that additionally enable safe operation. Observe all safety instructions without fail, observance serves your safety. Prior to commissioning the unit, the operator must ensure that all safety-related conditions are met. Adhere to the relevant accident prevention regulations as well as other generally accepted safety-related and occupational-medical regulations.
Page 14: Safety Notes Regarding Operation
› disregards the specified safety instructions. Maintenance and upkeep of the machine is only allowed to be carried out by personnel trained and certified by EXAKT. These personnel must be familiar with the machine and instructed on its dangers as well as have the required qualification.
Page 15 Safety WARNING Danger of being pulled in by the rollers: During operation, the rollers of the machine are driven. This causes a danger of being pulled in. › When working at the machine, pay attention to your hands and fingers. ›...
Page 16 Safety CAUTION Danger of cuts at the scraper knife. › During assembly and handling, always work with plastic knife protection or with knife protection for scraper socket. › When working with the scraper socket and scraper knife, wear suitable safety gloves. CAUTION Danger arising from the substances to be processed: The substances to be processed can cause health hazards.
Page 17: Safety Notes Regarding Cleaning Work
Safety 4.7. SAFETY NOTES REGARDING CLEANING WORK WARNING Danger of being pulled in by the rollers: During operation, the rollers of the machine are driven. This causes a danger of being pulled in. › When working at the machine, pay attention to your hands and fingers.
Page 18: Handling Chemical Substances And Coolants/Lubricants
Safety 4.8. HANDLING CHEMICAL SUBSTANCES AND COOLANTS/LUBRICANTS When handling oil, grease and other chemical substances, observe the corresponding safety data sheets and disposal instructions by the respective manufacturers and take all local safety requirements into account. CAUTION When handling chemical substances such as cleaning agents, cooling and temperature control media can cause hazards in case of contact with skin or eyes as well as inhalation.
Page 19: Cleaning Agents
Safety 4.9. CLEANING AGENTS When using cleaning agents, observe the corresponding safety data sheets and disposal instructions by the respective manufacturers and take all local safety requirements into account. WARNING Use of explosive or easily flammable cleaning agents constitutes an increased danger of explosion. Do not use explosive or easily flammable cleaning agents! 27891EN-900-02 / Edition 02/2017...
Page 20: Performance Specifications
Performance specifications PERFORMANCE SPECIFICATIONS 5.1. INTENDED USE Link back to chapter 3 Installation information in advance Intended use of this machine is only defined for the fields of industry, development, research and production for the quantities specified in the technical data. Any other use is considered improper. The spectrum of applications reaches from food industry to nanotechnology.
Page 21: No Release For Work In Potentially Explosive Atmosphere
Performance specifications 5.2. NO RELEASE FOR WORK IN POTENTIALLY EXPLOSIVE ATMOSPHERE Link back to chapter 3 Installation information in advance The machine has not been designed for use in potentially explosive areas. › Do not operate the machine in potentially explosive atmosphere. ›...
Page 22: Technical Condition
Performance specifications 5.5. TECHNICAL CONDITION If the machine is in a bad technical condition, both good function and safety are at risk. › Use the machine in technically good condition only. › Observe the maintenance intervals. › Rectify any machine faults if the usual behavior of the machine changes. ›...
Page 23: Marking
Performance specifications 5.9. MARKING 5.9.1. TYPE PLATE OF THE MACHINE Link back to chapter 3 Installation information in advance For identification purposes, the machine is equipped with an individual label: Article Voltage Description / Sign on number type plate 27100 380- Solidly grounded 420VAC...
Page 24 Performance specifications Article Voltage Description / Sign on number type plate 27105 200- Corner grounded 240VAC Delta (3 lines) 50-60Hz Japan, (USA) Fig. 3: Type plate of the machine 200-240V – Corner grounded Delta NOTE Danger of machine damage. The specification for voltage, frequency, and power consumption can vary depending on the version.
Page 25: Type Plate Of Operating Unit
Performance specifications 5.9.2. TYPE PLATE OF OPERATING UNIT For identification purposes, the operating unit is equipped with an individual label: Fig. 4: Type plate of the operating unit The type plate on the operating unit identifies ONLY the operating unit and not the machine! Observe the type plate of the machine.
Page 26: Technical Data
Technical data TECHNICAL DATA Link back to chapter 3 Installation information in advance Description Value Unit 6.1. ENVIRONMENT Ambient temperature 10 .. 40 °C 50 .. 95 °F Relative humidity, non condensing max. 85 6.2. OPERATING AND AUXILIARY MATERIALS Cooling / tempering fluid (thermofluid) Operation of the machine only with circulation cooling with a corrosion-protection/water mix.
Page 27: Airborne Sound Emission
Technical data Description Value Unit 6.4. AIRBORNE SOUND EMISSION Measured values, with product, 300rpm emitted sound pressure level dB(A) 6.5. DIMENSIONS 6.6. DIMENSIONS CRATE WxHxD 880x970x720 35x38x29 inch 6.7. ELECTRIC VALUES EU 3-phase mains connection Voltage 380 .. 420 VAC Control voltage Frequency 48 ..
Page 28: Ip Protection
Technical data Description Value Unit Control voltage Frequency 48 .. 63 Max. power consumption 1300 6.10. IP PROTECTION Ingress protection IP32 6.11. ROLLER TEMPERATURE CONTROL Max. pressure at: pressureless cooling 1.0 .. 4.0 14 .. 60 Max. pressure at: pressure cooling 0.5 ..
Page 29: Unit Description
Unit description UNIT DESCRIPTION 7.1. FUNCTIONAL PRINCIPLE The machine disperses, de-agglomerates and homogenizes powdered material to liquid or highly viscous suspensions. At the same time the product is degassed. The three rollers rotate reversely with various speeds in a speed ratio of approx.
Page 30: Overview
Unit description 7.2. OVERVIEW 7.2.1. SECTION VIEW Fig. 6: Section view a Roller 1 e Safety device gap 1 (nip b Roller 2 gap), divers c Roller 3 f Splash tray with safety d Plastic guides guard prevent an overflow of the product at the g Scraper knives, various roller ends.
Page 31: Operating Modes
Unit description 7.3. OPERATING MODES 7.3.1. CLEANING Fig. 7: Cleaning   Scraper removed Plastic guides removed   Cleaning guard mounted Rollers to max. gap value 7.3.2. MIXING Fig. 8: Mixing   Scraper swiveled off Knife guard mounted ...
Page 32: Gap-Force
Unit description 7.3.4. GAP-FORCE Fig, 10: Gap-Force   Scraper swiveled off Gap 1 in gap mode  Gap 2 in force mode NOTE Destruction or damage to the rollers. Machine must IN GENERAL be operated with product because else dry run of the rollers causes damage or destruction of the rollers.
Page 33: Emergency Stop
Unit description 7.4. EMERGENCY STOP Fig. 12: Emergency stop button a Emergency stop button   Drive motor stops Gap values to maximum gap width 27891EN-900-02 / Edition 02/2017...
Page 34: Safety Devices
Unit description 7.5. SAFETY DEVICES The safety devices prevent direct access to pull-in points as far as possible. For operation of the machine, the following must always be mounted:  Splash tray, safety sensor locked  Cleaning guard or safety device nip gap (gap 1) 7.5.1.
Page 35: Routine Operations
Unit description 7.5.2. ROUTINE OPERATIONS The various safety devices prevent access to the nip gap as far as possible. Fig. 14: Safety devices routine operations a Safety device nip gap, various c Splash tray with safety guard b Safety sensor, nip gap (gap 1) d Safety sensor, splash tray ...
Page 36: Safety Marks
Unit description 7.6. SAFETY MARKS Link back to chapter 3 Installation information in advance 7.6.1. DANGER OF CRUSHING Fig. 15: Warning note - danger of being pulled in by rotating rollers Danger of crushing if pulled in by rollers 7.6.2. DANGER OF CUTS Fig.
Page 37: Voltage
Unit description 7.6.3. VOLTAGE Fig. 17: Warning note voltage Warning of voltage 7.6.4. INCREASED LEAKAGE CURRENT Fig. 18: Warning note increased leakage current Warning of increased leakage current; fixed connection only! 27891EN-900-02 / Edition 02/2017...
Page 38: Tempering Fluid
Unit description 7.6.5. TEMPERING FLUID Fig. 19: Warning note tempering fluid Use corrosion protection, minimum and maximum supply temperature, maximum media pressure 27891EN-900-02 / Edition 02/2017...
Page 39: Control Elements
Unit description 7.7. CONTROL ELEMENTS 7.7.1. FRONT SIDE Fig. 20: Unit front side Key switch „Release Reverse“ a Roller 1 b Roller 2 k Emergency stop button, c Roller 3 locking d Safety device nip gap, various Scraper socket, with scraper e Operating unit knife, various f Start button...
Page 40: Backside
Unit description 7.7.2. BACKSIDE Fig. 21: Unit backside a Roller 1 k Connection for roller b Roller 2 temperature control (return c Roller 3 flow) d Safety device nip gap, various Locking cock inlet flow e Operating unit m Level indication return flow f Main switch ON/OFF, lockable (only with pressure-free g Fuses...
Page 41: Roller Temperature Control
For the temperature control of the three roller mill 80E PLUS, EXAKT recommends using the cooling circulator bath thermostat by HUBER, model MPC-K6. The unit can be procured via EXAKT and is then delivered with tube connections matching the three roller mill and with optimum control configuration.
Page 42: Pressureless Cooling
Unit description 7.8.1. PRESSURELESS COOLING NOTE Danger of destruction of device components › Check coolant filling level during operation. › If the filling level is steadily increasing in the green area or latest if it is too high as indicated by the red area, there is a risk that coolant will overflow within the machine.
Page 43 Unit description Fig. 23: Pressureless cooling, level indication return flow tank a Locking cock b Level indication return flow trough 27891EN-900-02 / Edition 02/2017...
Page 44: Pressure Cooling
Unit description 7.8.2. PRESSURE COOLING NOTE Danger of destroying the seals in the rotary units (b). › With pressure cooling, always ensure coolant flow during operation. Fig. 24: Pressureless cooling, flow-through direction standard a Locking cock c Temperature sensor (3x) b Rotary unit (3x) ...
Page 45: Scraper System
Unit description 7.9. SCRAPER SYSTEM The scraper system consists of the scraper socket with exchangeable scraper knife (various materials) that is swiveled to roller 3 to scrape off the product. Fig. 25: Scraper socket with exchangeable scraper knife a Scraper knife c Adaptor b Scraper socket 7.10.
Page 46: Scope Of Delivery
Unit description 7.11. SCOPE OF DELIVERY Symbol Meaning Base unit roller material: either - hard chrome plated steel - tungsten carbide coated steel - aluminum oxide - silicon carbide Load traverse (installed for delivery) (To lift the machine and to secure it in the transport box).
Page 47 Unit description Symbol Meaning Splash tray Scraper socket (with exchangeable scraper knife) Knife guard (to be placed onto scraper socket during handling, mounting, mixing operation) Scraper bolt 1mm for scraper angle 110 ° Scraper bolt 4mm for scraper angle 115 ° (by default mounted in scraper socket) By default mounted in scraper socket...
Page 48 Unit description Symbol Meaning Allen screwdriver 6 mm (for all safety devices) Petroleum jelly 100 ml Spatula Operating instructions Sheet with safety instructions Edition 09/2016...
Page 49: Equipment Variants
Steel, hard chrome plated Steel, tungsten carbide coated Roller materials Aluminum oxide Silicon carbide Safety Additional antenna stop buttons (2x) External interfaces for EXAKT bus and optionally: Interfaces Emergency stop button Start-stop button Version with heavy duty connector (HARTING) Electrical connection as "pluggable"...
Page 50: Safety Devices Nip Gap And Optional Accessories
Unit description 7.13. SAFETY DEVICES NIP GAP AND OPTIONAL ACCESSORIES The following safety devices and options are available for the EXAKT 80E Plus. The information in "mm" refer to the working width. The machine is always delivered with at least one safety device: 7.13.1.
Page 51: Optional Accessories
Unit description Safety devices Description Safety bridge 170 mm, only for products that are hard to process! Pull-in protection 85 mm Safety bridge 85 mm, only for products that are hard to process! 7.13.2. OPTIONAL ACCESSORIES Optional accessories Description Plastic guides working width 200 mm Splash guard side plates, set (removable, for easy cleaning) Splash guard, set (for 200 mm working width)
Page 52 Unit description Optional accessories Description Guide shaft 170 mm, blue and black Guide shaft 85 mm, blue and black Scraper knife, various versions Scraper constriction 60 mm Roller cover with adapter for aspiration Solvent dispenser for guide lubrication, set (in some cases it is required to lubricate the plastic guides additionally against running dry) Protective cover Plastic spatula...
Page 53: Transport
Immediately at delivery by the carrier, check if the sensor is intact. If not, notify the carrier immediately and let the driver confirm this. The transfer of risk from manufacturer to final customer takes place with leaving the factory premises of EXAKT / Germany. NOTE Danger of damaging machine components.
Page 54: Intermediate Storage
Immediately at delivery by the carrier, check if the sensor is intact. If not, notify the carrier immediately and let the driver confirm this. The transfer of risk from manufacturer to final customer takes place with leaving the factory premises of EXAKT / Germany. Edition 09/2016...
Page 55 Transport Abb. 27: Machine crate Abb. 28: Remove crate top cover 1. Unscrew the crate top cover (a), 10 screws. Abb. 29: Take out machine accessories Abb. 30: Remove intermediate cover 2. Take out the machine accessoires and store it at a safe place.. 3.
Page 56 Transport ~12 kg ~26,5 lb Abb. 31: Remove the screws and lift the crate outside frame 5. Remove the 10 screws for the crate outside frame (c). 6. Lift the crate outside frame securely to the top (2 persons). NOTE Danger of component damage.
Page 57: Instructions For Lifting
(see chapter 6 Technical data). › Lifting aids must be in perfect condition. › Lift machine only with the original load traverse provided by EXAKT. › Take up the machine in the 2 heavy load clevis (a).
Page 58 Transport 120 kg 265 lb Fig. 34: Lifting the machine › The angle of the lifting rope must not exceed 60°! Secure the lifting rope against slipping out of place (e.g. loop around the fork of the fork lifter, see b) ›...
Page 59: Moving The Machine By Hand
Transport 8.4.1. MOVING THE MACHINE BY HAND The machine can be moved by hand. For this purpose, recessed grips provided on the left and the right below the machine. 120 kg 265 lb Fig. 35: Lifting the machine by hand ›...
Page 60: Installation
Installation INSTALLATION 9.1. SETUP SITE Link back to chapter 3 Installation information in advance Fig. 36: Setup site and dimensions 27891EN-900-02 / Edition 02/2017...
Page 61 › The setup site must meet the specifications given in the safety data sheets of the substances to be processed, especially when working with highly volatile solvents. › Lift machine only with the original load handling equipment provided by EXAKT. › After installation, dismount load handling equipment and store safely. WARNING Suspended load...
Page 62: Dismounting The Load Traverse
Installation 9.2. DISMOUNTING THE LOAD TRAVERSE Allen screwdriver 6 mm Fig. 37: Dismounting the load traverse › After setup, dismount the load traverse. 1. Undo 2 Allen screws (a) and remove load traverse carefully. Do not damage the rollers in this step! 2.
Page 63: Mounting And Aligning The Operating Unit
Installation 9.3. MOUNTING AND ALIGNING THE OPERATING UNIT Allen screwdriver 6 mm Fig. 38: Mounting the operating unit Fig. 39: Connecting the plug connections 1. Mount the operating unit (a) in the holder arm (b) with the screw (c) and the washer (d).
Page 64: Connecting The Electric Supply
Installation 9.4. CONNECTING THE ELECTRIC SUPPLY Link back to chapter 3 Installation information in advance WARNING Danger of electric shock! Incorrect mounting of the connecting cable can cause severe injury due to electric shock. › Only allow a trained electrician to connect the machine. The electrical installation of the unit must be done by specialized personnel who are qualified according to the local or legal requirements and regulations.
Page 65: Connect Variant 1: Fixed Connection
Installation 9.4.2. CONNECT VARIANT 1: FIXED CONNECTION We recommend to select a fixed connection for the unit. This connection variant does not require a ground fault circuit interrupter and ensure proper operation. Label (color) Mains supply 400 V 200 V (USA, Jap.) N (MP) N (black) L1 (black)
Page 66: Connection Variant 2: Fixed Connection With Coded Heavy Duty Connector
WITH CODED HEAVY DUTY CONNECTOR Link back to chapter 3 Installation information in advance Upon request, EXAKT will deliver the machine with heavy duty connector HARTING type: Han 6x. This connection variant does not require a ground fault circuit interrupter and ensure proper operation.
Page 67 Installation Fig. 42: Connection variant 2: fixed connection with coded heavy duty connector Coding HARTING socket / connector Coding pin at pin 1 (socket, top view) 400V 200V (USA, Jap) Coding pin at pin 4 (socket, top view) 27891EN-900-02 / Edition 02/2017...
Page 68: Connection Variant 3: Connection Via Three-Poles Standard Plug (Min. 15A)
Installation 9.4.4. CONNECTION VARIANT 3: CONNECTION VIA THREE-POLES STANDARD PLUG (MIN. 15A) If the unit is equipped with a three-pole standard connector (in Germany e.g. CEE plug 16A acc. to DIN EN 60309), an RCCB type B 30mA acc. to DIN EN 61008 must be installed in the system to be connected.
Page 69 Installation Label (color) Mains supply 400 V 200 V (USA, Jap.) N (MP) N (black) L1 (black) L2 (black) L3 (black) none (green/yellow) PE rail none (16 mm² green/yellow) Eye 8 mm 27891EN-900-02 / Edition 02/2017...
Page 70: Connecting The Roller Temperature Control
For the temperature control of the three roller mill 80E PLUS, EXAKT recommends using the cooling circulator bath thermostat by HUBER, model MPC-K6. The unit can be procured via EXAKT and is then delivered with tube connections matching the three roller mill and with optimum control configuration.
Page 71: With Pressureless Cooling
Installation NOTE Danger of roller damage: Using a tempering fluid without corrosion protection results in corrosion inside the rollers. Observe the coolant specification (see chapter 6 Technical data). NOTE Danger of damaging the rollers: 5. Inlet flow temperature of the rollers min. 10 °C (50 °F) to max. 55 °C (130 °F).
Page 72: With Pressure Cooling
Installation 9.5.3. WITH PRESSURE COOLING Link back to chapter 3 Installation information in advance NOTE Danger of destroying the seals in the rotary units › With pressure cooling, always ensure coolant flow during operation. 9.6. CHECKLIST INSTALLATION Description Load traverse dismounted. M8x20 screws are mounted. Electrical connection completed.
Page 73: Setup
Setup SETUP In this section, the following mounting and installation tasks are described for:  Cleaning the machine housing  Scraper knife and scraper  Knife guard  Splash tray  Cleaning guard  Plastic guide for working widths 85, 170, 200 mm ...
Page 74: Scraper Knife Types
Setup 10.2. SCRAPER KNIFE TYPES The different scraper knives can be combined with the various roller types as follows: Roller type Scraper knife Tungsten Hard chrome Al2O3 carbide Art.-No. Des. Metal, ZrO2 27320 (hybrid knife) 218x0.35x30 Solidknife ZrO2 27325 218x0.63x25 nickel-plated 27330 218x0.35x30...
Page 75: Mounting The Scraper Knife
Setup 10.3. MOUNTING THE SCRAPER KNIFE CAUTION Danger of cuts at the scraper knife. › During assembly and handling, ALWAYS work with plastic knife protection or with knife protection for scraper socket. › When working with the scraper socket and scraper knife, wear suitable safety gloves.
Page 76 Setup 1. Before assembly, clean all parts. 2. Mount scraper bar (e) with 3 screws (c) to the scraper socket (a). 3. Loosen the clamping screws (b). 4. Insert scraper knife (f) (with plastic knife guard). Make sure that the sharp edge points forwards and the sharpened side of the knife edge points up, i.e.
Page 77: Combination Scraper Knife - Scraper Bar - Adaptor
Setup 10.3.1. COMBINATION SCRAPER KNIFE – SCRAPER BAR - ADAPTOR The different scraper knives (f) need different scraper bars (e) and adaptors (d). Scraper bar (e) Scraper knife (f) Adaptor (d) Silver Black 27394 27393 Art.-No. Des. Metal, ZrO2 2 mm 27320 (hybrid knife) 27392...
Page 78: Putting On The Knife Guard
Setup 10.4. PUTTING ON THE KNIFE GUARD The knife guard for the scraper socket protects from cuts during: › Removing the scraper socket and putting it into place › Storing the scraper socket › Mixing operation while the scraper is swiveled off For rapid access, the knife guard can be fastened with magnets on the machine while it is not in use.
Page 79: Adjusting The Scraper Contact Pressure
Setup 10.5. ADJUSTING THE SCRAPER CONTACT PRESSURE The contact pressure of the scraper system is generated by an adjustable tension spring. The tension spring is adjusted via the adjustment wheel (a). The hand (b) displays the value on a scale. Low scale value = low contact pressure, high scale value = high contact pressure Fig.
Page 80: Mounting The Scraper Socket
Setup If the contact pressure is too high or too low, product removal might deteriorate. Contact pressure too high increases wear of the scraper knife. At first installation, the contact pressure is set to minimum pressure. For the characteristics if the contact pressure is too low, refer to chapter 15 Troubleshooting.
Page 81 Setup Fig. 50: Set scraper onto scraper base 4. Check location hole at the scraper for impurities. 5. Set scraper socket (with scraper knife and knife guard for scraper socket) onto the two pin receptacles. Make sure that the scraper socket sits completely and is not "tilted".
Page 82: Aligning The Scraper Socket In Parallel To The Roller
Setup 10.7. ALIGNING THE SCRAPER SOCKET IN PARALLEL TO THE ROLLER Allen screwdriver 6 mm Fig. 53: Aligning the scraper socket in parallel 1. Swivel the scraper socket (b) to the roller with the knife inserted. 2. Undo the fixing screw (a) slightly with Allen screwdriver so that the scraper base with scraper socket in place can move freely.
Page 83: Setup Of The Scraper Angle
Setup 10.8. SETUP OF THE SCRAPER ANGLE Allen screwdriver 4 mm The scraper angle can be set in 3 different positions. Depending on the product, it might be required to adjust the angle for removing the product. For this purpose, scraper bolts with different lengths are screwed to the scraper socket to change the tangent angle of the scraper knife to the roller.
Page 84: Mounting The Splash Tray
Setup 10.9. MOUNTING THE SPLASH TRAY Allen screwdriver 6 mm Fig. 55: Mounting the splash tray 1. Swivel off scraper lever (a) until locking lever (b) snaps in. 2. Push in splash tray (c) from the front. Make sure that the splash tray does not touch the rollers.
Page 85: Mounting The Cleaning Guard
Setup 10.10. MOUNTING THE CLEANING GUARD When cleaning the roller surfaces, the cleaning guard prevents body parts or foreign objects (e.g. cleaning towel) being pulled in and thus prevents the components being destroyed. Allen screwdriver 6 mm WARNING Danger of being pulled in by the rollers during cleaning ›...
Page 86 Setup NOTE The centering mounts (d) fix all safety devices for the nip gap in the correct position. › Make sure that the safety device sit well on the centering mounts before securing the latches. 2. Swivel in left latch (b) and right latch (c) successively. 3.
Page 87: Inserting Plastic Guides For Working Width 85 Mm And 170 Mm
Setup 10.11. INSERTING PLASTIC GUIDES FOR WORKING WIDTH 85 MM AND 170 MM WARNING Danger of being pulled in by the rollers in case of incorrect length of the guide shafts: › Always select the same length for both guide shafts matching the selected working width.
Page 88 Setup Fig. 57: Plastic guide WW 85mm and 170mm: Assembling parts 1. Select guide shafts for the desired working width 2. Screw guide shaft (b, c) into plastic guide (a) hand-tight. 3. For working with hopper, additionally push the springs (d) onto the guide shafts 170.
Page 89: Mounting Plastic Guides For Working Width 200 Mm
Setup 10.12. MOUNTING PLASTIC GUIDES FOR WORKING WIDTH 200 MM Allen screwdriver 4 mm NOTE Roller destruction due to incorrect input of the working width (E-models) › In general, program the working width of the used safety device via the operating unit.
Page 90 Setup Fig. 59: Plastic guide working width 200mm: assembling parts 1. Screw together plastic guide - shoulder guide (a) with top for shoulder guide (b) / top shoulder guide, hopper (b.1). Pay attention to the color code with the blue or black screw, respectively. The front edges of the plastic guide and the tops must be flush.
Page 91 Setup 5. Use an Allen screwdriver to turn the clamping cone (h) all the way up. Fig. 61: Inserting plastic guides for working width 200 mm (shoulder roller) (here: with top for shoulder guide) Fig. 62: Inserting plastic guides for working width 200 mm (shoulder roller) (here: with top for shoulder guide, hopper) 6.
Page 92: Mounting The Safety Device Nip Gap, Working Widths 85 Mm, 170 Mm, 200 Mm
Setup 10.13. MOUNTING THE SAFETY DEVICE NIP GAP, WORKING WIDTHS 85 MM, 170 MM, 200 MM Allen screwdriver 6 mm NOTE Roller destruction due to incorrect input of the working width (E-models) › In general, program the working width of the used safety device via the operating unit.
Page 93: Mounting Hopper For Working Width 170 Mm
Setup 3. Swivel in latch (c) and latch (d) successively. 4. Secure both latches successively with Allen screwdriver. 10.14. MOUNTING HOPPER FOR WORKING WIDTH 170 MM Allen screwdriver 6 mm NOTE Roller destruction due to incorrect input of the working width (E-models) ›...
Page 94 Setup Fig. 64: Mounting hopper for working width 170 mm 1. Mount plastic guide 170 mm with springs (see chapter 10.11 Inserting plastic guides for working width 85 mm and 170 mm). 2. Mount hopper base (a). In doing so, push in the plastic guides completely against the spring pressure.
Page 95: Mounting Hopper For Working Width 200 Mm
Setup 10.15. MOUNTING HOPPER FOR WORKING WIDTH 200 MM Allen screwdriver 4 mm, 6 mm NOTE Roller destruction due to incorrect input of the working width (E-models) › In general, program the working width of the used safety device via the operating unit.
Page 96: Mounting Splash Guards For Working Width 200 Mm
Setup 10.16. MOUNTING SPLASH GUARDS FOR WORKING WIDTH 200 MM Allen screwdriver 6 mm Whenever necessary, the two splash guards (a) prevent the product being ejected from the first roller and darting through the room. Fig. 66: Mounting splash guard for working width 200mm 1.
Page 97: Mounting Splash Guards For Inner Side Paneling
Setup 10.17. MOUNTING SPLASH GUARDS FOR INNER SIDE PANELING Allen screwdriver 6 mm The splash guards (a) for the inner side paneling facilitate cleaning the side paneling as the plates can be removed for cleaning. Fig. 67: Mounting splash guard for inner paneling ›...
Page 98: Mounting The Solvent Dispenser For Guide Lubrication
Setup 10.18. MOUNTING THE SOLVENT DISPENSER FOR GUIDE LUBRICATION Allen screwdriver 6 mm Open-ended spanner 22 mm NOTE Destruction of rollers with working widths 85 mm and 170 mm in force mode (E-models): Due to low gap widths and high line pressure, we recommend to operate the machine with a solvent dispenser for guide lubrication in force mode in order to enhance protection of the rollers against damage.
Page 99: Operating Elements And Operating Unit
For the complete menu guide of the operating unit, refer to the separately provided operating instructions "Operating unit EXAKT E Plus". 11.1. MAIN SWITCH The main switch (a) switches the power of the machine on or off.
Page 100: Operating Panel
Operating elements and operating unit 11.2. OPERATING PANEL The operating panel controls the basic functions of the machine such as: › Start and stop of the roller drive. › Receipt safety of the safety devices. › Reversing in case of overload or foreign objects being pulled in, in order to move the product / foreign object in reverse direction out of gap 1.
Page 101: Emergency Stop Button
Operating elements and operating unit 11.3. EMERGENCY STOP BUTTON Fig. 71: Actuating the emergency stop button Fig. 72: Unlocking the emergency stop button 1. Actuate emergency stop button. 2. Rectify the fault. 3. Unlock the red button of the emergency stop button. 4.
Page 102: Operating Unit
Operating elements and operating unit 11.4. OPERATING UNIT The operating unit takes over all functions to control the machine during operation: › Cleaning mode. › Routine operations with setting of the operating parameters such as rotational speed, gap or force mode. ›...
Page 103 Operating elements and operating unit Fig. 74: Layout of the user interface, three parts, shown: routine operations a Upper display field g Enable for control dial with b Center display field inner red arrow control dial c Lower display field can additionally be pressed to d Status messages safety select other modes...
Page 104: Safety Messages On The Display
Operating elements and operating unit 11.4.1. SAFETY MESSAGES ON THE DISPLAY For operation of the machine, all safety devices must be mounted correctly. This is monitored by the safety circuit, roller start will else not be released. Incorrectly mounted safety devices or unsafe conditions are indicated on the display.
Page 105 Operating elements and operating unit › Check that the respective safety device has been mounted correctly according to these instructions. › In case of EMERGENCY STOP: Rectify fault and unlock button  After the fault has been rectified and/or mounting has done correctly, you automatically jump to the selected menu.
Page 106: Overload Messages On The Display
Operating elements and operating unit 11.4.2. OVERLOAD MESSAGES ON THE DISPLAY The roller drive automatically stops in case of overload to protect the machine. Such events are indicated by the following messages: Fig. 80: Force exceeded - Line pressure too high Fig.
Page 107: Program Structure
Operating elements and operating unit 11.5. PROGRAM STRUCTURE 27891EN-900-02 / Edition 02/2017...
Page 108: Operation
Operation OPERATION This section describes operation of the three roller mill: › Switching on the machine. › Cleaning the rollers. › Adjust the machine. › Defining the pre-settings (setup) › Routine operations: Test run with petroleum jelly. WARNING Danger of being pulled in by the rollers: During operation, the rollers of the machine are driven.
Page 109 Operation WARNING Danger of eye injuries due to rotating rollers or when handling product and cleaning agents › In general, wear eye protection. › Wear suitable protective clothing. CAUTION Danger of cuts at the scraper knife. › During assembly and handling, always work with plastic knife protection or with knife protection for scraper socket.
Page 110: Switching On The Machine
Operation 12.1. SWITCHING ON THE MACHINE 1. Switch on the machine via the main switch.  The machine starts and the operating unit boots with the following screen: Machine operation only by authorized and trained staff ! Fig. 83: Start screen Fig.
Page 111 Operation Machine operation only by authorized and trained staff ! Fig. 85: Main menu a Period of operation f Settings b Next service g Adjusting the rollers c Term of payment h Cleaning menu d Program menu e Maintenance menu 27891EN-900-02 / Edition 02/2017...
Page 112: Cleaning The Rollers
Operation 12.2. CLEANING THE ROLLERS Allen screwdriver 6 mm In the cleaning menu, the rollers are cleaned by the user, afterwards the adjustment run for the roller distance can be started. The cleaning guard must be mounted. In cleaning mode, the speed is set to 30 rpm. The maximum speed is limited to 200 rpm (70 rpm in the US).
Page 113 Operation Fig. 86: Folded cleaning towel 7. Wet cleaning towel with cleaning agent. 8. Start drive and set desired speed. Fig. 87: Menu cleaning mode a Roller speed c Reversing mode b Adjusting the rollers d Back to start screen 27891EN-900-02 / Edition 02/2017...
Page 114: Cleaning Roller
Operation 12.2.3. CLEANING ROLLER 1 Fig. 88: Cleaning roller 1 › Place cleaning towel as far away from the roller gap as possible and move to and fro. 12.2.4. CLEANING ROLLER 2 AND ROLLER 3 Fig. 89: Cleaning roller 2 and roller 3 ›...
Page 115: Cleaning The Scraper System
Operation 12.3. CLEANING THE SCRAPER SYSTEM The scraper system must be cleaned after every use. In addition, it might be necessary to clean or change the scraper system even between two passes. This prevents mixing of the fine parts of the raw product and the already dispersed product.
Page 116: Adjusting The Rollers
Operation 12.5. ADJUSTING THE ROLLERS NOTE Danger of destroying components: It is possible to skip cleaning mode and start directly with adjustment. › ALWAYS CLEAN the machine before adjustment. › Scraper swiveled off or dismounted (knife guard mounted). › Plastic guides dismounted. ›...
Page 117: Defining The Pre-Settings (Setup)
Operation 12.6. DEFINING THE PRE-SETTINGS (SETUP) In the pre-settings (setup), you set the selected working width and the instruction for the temperature settings of an external temperature control unit. In general, the working width must be set matching to the used safety device.
Page 118: Setup After Every Adjustment And Before Each Programming
Operation 12.6.1. SETUP AFTER EVERY ADJUSTMENT AND BEFORE EACH PROGRAMMING After every adjustment of the rollers or before every creation of a program, the setup menu is displayed automatically. Fig. 92: Setup - Setting working width and temperature Fig. 93: Continue in routine operations 1.
Page 119: Select Setup Via Menu Item Select Setting (In Routine Operations)
Operation 12.6.2. SELECT SETUP VIA MENU ITEM SELECT SETTING (IN ROUTINE OPERATIONS) 1. Select menu item Settings 2. Select Setup Fig. 94: Select menu selection Fig. 95: Select setup 3. Select working width with control dial (a) out of 85 / 170 und 200 mm. 4.
Page 120 Operation 5. Confirm with 6. Back to routine operations with Fig. 98: Display values for working width and temperature setting instruction for external temperature control unit 27891EN-900-02 / Edition 02/2017...
Page 121: Routine Operations
Operation 12.7. ROUTINE OPERATIONS Fig. 99: Display routine operations, numerical view a Display gap 1 h Program menu b Gap width [Inc] Menu DataLog c Line pressure [N/mm] Display process data, change d Settings working width between graphical, schematic e Temperature display(s) and numeric display f Display gap 2 k Settings...
Page 122 Operation › By pressing the control keys you can switch between graphical, schematic and numeric display. The set parameters remain. Fig. 100: Graphical display process parameters Fig. 101: Schematic display 27891EN-900-02 / Edition 02/2017...
Page 123: Routine Operations: Test Run With Petroleum Jelly
Operation 12.8. ROUTINE OPERATIONS: TEST RUN WITH PETROLEUM JELLY NOTE Roller destruction due to incorrect input of the working width (E-models) › In general, program the working width of the used safety device via the operating unit. Else the line force values [N/mm] will not correspond. Danger of roller destruction in force mode.
Page 124: Optimum Product Flow
Operation It is important that nip gap and scraper gap are coordinated. The product film should have an even width on all rollers and an even thickness per roller. The setting ratio from gap 1 to gap 2 should not exceed the value of approx.
Page 125 Operation Fig. 104: Ratio gap 1 / gap 2 too large If gap 2 is set relatively too tight, the product will flow laterally outwards and causes leaks of the plastic guides (working widths 85 mm and 170 mm) because the product is transported back from the center roller back to gap 1 over the newly created width.
Page 126: Reverse Function
Operation 12.9. REVERSE FUNCTION In reversing mode, the rollers rotate backwards and foreign objects or a product jam can be removed. WARNING Danger of being pulled in by the rollers: In reversing mode, gap 2 becomes the nip gap. Increased risk of being pulled in because this gap is not covered by a safety device.
Page 127 Operation Fig. 105: Select reversing Fig. 106: Key switch must be switched 3. Unlock right latch of the cleaning guard (deactivate cleaning mode). Fig. 107: Display: “Press start button reversing mode” Fig. 108: Deactivating cleaning mode 4. Press start button reversing mode (a). 5.
Page 128: Sequence From Routine Operations
Operation 12.9.2. SEQUENCE FROM ROUTINE OPERATIONS › Splash tray must be mounted. › Safety device at nip gap (gap 1) is mounted. If a foreign object was pulled in, it can be helpful to mount the safety bridge before reversing, depending on the employed safety bridge.
Page 129: Checking The Safety Devices
Operation 12.10. CHECKING THE SAFETY DEVICES Allen screwdriver 6 mm 12.10.1. PREPARING FOR CHECK 1. Dismount scraper. Use knife guard. 2. Mount splash tray. 3. Mount cleaning guard. 4. Press receipt safety button. 5. Select cleaning mode. 6. Start machine at 30 rpm. 12.10.2.
Page 130: Maintenance
Maintenance MAINTENANCE EXAKT units are, if operated properly and checked for safety, very reliable and low-maintenance. To ensure this, the following service and maintenance works must be done in the specified intervals according to maintenance plan. EXAKT recommends annual maintenance by EXAKT or by a dealer authorized by EXAKT.
Page 131: Cleaning The Machine Housing
Maintenance 13.1. CLEANING THE MACHINE HOUSING CAUTION When handling chemical substances such as cleaning agents, cooling and temperature control media can cause hazards in case of contact with skin or eyes as well as inhalation. Provide suitable exhaust and wear safety goggles, safety gloves and protective clothing.
Page 132: Maintenance And Care
Maintenance and care MAINTENANCE AND CARE EXAKT units are, if operated properly, very reliable and low-maintenance. To ensure this, the following service and maintenance works must be done in the specified intervals according to maintenance plan. WARNING Prior to performing service and maintenance tasks, read the...
Page 133: Service And Maintenance Plan
Maintenance and care 14.1. SERVICE AND MAINTENANCE PLAN Service and maintenance Chapter Schedule System works After each Plastic Check plastic guides for dirt and use and guides wear, clean / replace if product Rollers necessary. change Clean rollers and run visual check for wear.
Page 134 Maintenance and care Schedule System Service and maintenance works Chapter 1500h / Machine Clean inside. 12 months Rollers Check geometry. Maintenance by EXAKT: Lever Check status, mechanics check adjustment function Drive belt Replace, tension. Drive belt for Replace. tensioning / deflector pulleys...
Page 135: Troubleshooting
Drive belt insufficiently Tension or let be replaced by machine side. tensioned or defective. EXAKT Service. Belt tensioner or deflector replace / EXAKT Service. pulley worn. Toothed wheel defective. replace / EXAKT Service. Product fineness Rollers damaged. replace / EXAKT Service.
Page 136 Roller adjustment not Clean machine and adjust parallel. machine again. Contact EXAKT Service if necessary. Product flows Plastic guides dirty or Clean, replace if necessary. below the plastic worn.
Page 137 Troubleshooting Description Cause Remedy Product diverges Gap 1 (nip gap) in ratio to Reduce gap width of gap 1 or laterally on the gap 2 too large, this increase gap width of gap 2. rollers, possibly causes more product to the beyond the roller pulled in than gap 2 can ends.
Page 138: Shutting Down
Shutting down 16 SHUTTING DOWN 16.1. SHORT-TERM SHUTTING DOWN › Cleaning the rollers. › Clean and store all accessories. › Clean machine housing. › If necessary, drain tempering fluid completely. › Secure machine against unauthorized switching on (padlock at main switch). ›...
Page 139: Disposal
Disposal DISPOSAL 17.1. DISPOSING OF PACKAGING The packaging of the machine consists of wood, cardboard and plastic insulation material. For disposal of the packaging, please observe the valid local regulations. 17.2. DISPOSING OPERATING MATERIALS AND CLEANING AGENTS When using operating materials (e.g. tempering fluid) and/or cleaning fluid, observe the corresponding safety data sheets and disposal instructions of the respective manufacturer and the local valid regulations...
Page 140: Spare And Wear Parts
Spare and wear parts SPARE AND WEAR PARTS You can order all spare parts, consumables and accessories from your specialized supplier. 18.1. WEAR PARTS 80S PLUS, 80E PLUS Article Description Quantity number Begrenzungsbacke Plastic guide 27300 Federsatz Backenstange, 10Stk. 27305 Springs guide shaft, 10pcs.
Page 141 Spare and wear parts Article Description Quantity number Abnehmermesser, hartverchromt 27350 Scraper knife,hard-chrome plated Abnehmermesser, PVC, rot 27360 Scraper knife, PVC, red Abnehmermesser, Epoxy, gelb 27370 Scraper knife, epoxy, yellow Abnehmermesser, Keramik, ZrO2 27380 Scraper knife, ceramic, ZrO2 Abnehmermesser, Keramik, Al2O3 27390 Scraper knife, ceramic, Al2O3 Begrenzungsbacke-...
Page 142 Spare and wear parts Article Description Quantity number Spatel weiss, 185x38 mm, 10Stck. 19910 Spatula white, 185x38 mm, 10pcs. Spatel weiss, 185x51 mm, 10Stck. 19911 Spatula white, 185x51 mm, 10pcs. Spatel weiss, 185x76 mm, 10Stck. 19912 Spatula white, 185x76 mm, 10pcs.
Page 143: Spare Parts 80S Plus, 80E Plus
Spare and wear parts 18.2. SPARE PARTS 80S PLUS, 80E PLUS Article Description Quantity number 200V-Maschine (US,Jap): Sicherung F401..403 10AT / träge (10Stck.) B4019 200V-Machine (US,Jap): fuse F401..403 10AT / time-lag (10pcs.) 400V-Maschine (EU): Sicherung F401..403 6,3AT / träge (10Stck.) B4020 400V-Machine (EU): fuse F401..403 6,3AT / time-lag (10pcs.)
Page 144 Spare and wear parts Article Description Quantity number Abnehmersockel, eloxiert 27341 Scraper socket, anodized Abnehmersockel, 27342 Scraper socket, Klemmstreifen 1mm für Abnehmermesser 27391 Adaptor 1mm for scraper knife Klemmstreifen 2mm für Abnehmermesser 27392 Adaptor 2mm for scraper knife Abnehmerleiste für Solid knife, schwarz Scraper bar for 27393...
Page 145 Spare and wear parts Article Description Quantity number Abnehmerstift 1mm / 110° (2x) incl. 2 Schrauben M5x35. Scraper bolt 1mm / 110° 27397 (2x) incl. 2 screws M5x35 Abnehmerstift 4mm / 115° (2x) incl. 2 Schrauben M5x35. Scraper bolt 4mm / 115° (2x) 27398 incl.
Page 146: Conformity Check
Conformity check CONFORMITY CHECK 19.1. CHECKING THE CONFORMITY Only operate the machine after personnel authorized by EXAKT have performs the installation and instruction. During installation and instruction, the corresponding installation and instruction checklists are worked off. 27891EN-900-02 / Edition 02/2017...
Page 147: Index
Index INDEX Emergency stop button ...... 37 Enable for control dial ...... 101 Adaptor ......... 43, 74 Equipment variants ......47 Adjustment ........114 External interface ....... 47 Allen screwdriver ........ 45 External interfaces (optional) ..... 38 Aluminum oxide ........44 Antenna stop switch ......
Page 148 Index Product flow ........122 Protective cover ........50 Key switch ........... 37 Pull-in protection ......... 48 Key switch „Release Reverse“ ... 37 Pushbutton ........100 Knife edge ........... 74 Knife guard ........29, 76 Receipt safety ........98 Receipt safety button ......37 Latch ...........
Page 149 Index Scraper system ........43 Stop button ......... 37 Service questions ......... 6 Setting dial for scraper force ..37, 77 Temperature control ......68 Setup site ..........58 Temperature control of the rollers ... 113 Sheet with safety instructions..... 46 Temperature control unit ....
Page 150: Annex
Impairment of unit function due to using incorrect spare parts or operating materials; the manufacturer warranty becomes void! When using not approved spare parts or operating materials, the unit function is not ensured, warranty becomes void. Only use original or EXAKT-approved spare parts and operating materials. 27891EN-900-02 / Edition 02/2017...
Page 151: Declaration Of Conformity
EC Directive. In case of modifications to the machine not approved by us, this declaration becomes void. Designation of the EXAKT Belt System: 300, 310, 311 machine: CL / CLV / CP / CPV Applied harmonized EN 60335-1...
Page 154 EXAKT ADVANCED TECHNOLOGIES GMBH Robert-Koch-Straße 5 D-22851 Norderstedt/Germany T +49 (0)40.52 95 60-0 F +49 (0)40.5 24 99 59 info@exakt.de · www.exakt.de...

Exakt 80E Plus + Operating Instructions Manual

1 Table of Contents

2 Contact Addresses

3 Installation Information in Advance

4 Safety

5 Performance Specifications

6 Technical Data

7 Unit Description

8 Transport

9 Installation

10 Setup

11 Operating Elements and Operating Unit

12 Operation

13 Maintenance

14 Maintenance and Care

15 Troubleshooting

16 Shutting down

17 Disposal

18 Spare and Wear Parts

19 Conformity Check

20 Index

21 Annex

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for Exakt 80E Plus +

Table of Contents