Retsch BB 300 User Manual

Operating instructions for jaw crusher type BB300

Retsch GmbH , 42781 Haan , Retsch-Allee 1-5, Germany 2/7/2012 0002

Notes on the operating instructions

These operating instructions for the jaw crusher type BB 300 provide all the necessary information on the topics listed in the table of contents. The guide the target group(s) defined for the relevant subjects in safe and proper handling of the BB 300. Knowledge of the relevant chapters by the appropriate target group(s) is essential for safe and proper handling. This technical documentation comprises a reference work and a training guide. The individual chapters are self-contained units. These operating instructions do not contain any instructions on repairs. Should any repairs become necessary, please contact your supplier or Retsch GmbH.

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Notes on the operating instructions .................................................. 2

Safety .................................................................................................. 4

Notes on safety............................................................................................... 4

Warning symbols ............................................................................................ 5

Repairs ............................................................................................................. 5

Confirmation .................................................................................................. 5

Technical data .................................................................................... 6

Use for the intended purpose ...................................................................... 6

Gap adjustment .............................................................................................. 6

Throughput, final fineness............................................................................ 6

Degree of protection .................................................................................... 6

Rated power .................................................................................................... 6

Noise data ....................................................................................................... 6

Equipment dimensions ................................................................................. 7

Mounting surface required ........................................................................... 7

Dimensional chart .............................................................................. 8

Transport and installation .................................................................. 9

Packaging ......................................................................................................... 9

Transport ......................................................................................................... 9

Interim storage ............................................................................................... 9

Parameters for the installation location ...................................................... 10

Installation....................................................................................................... 10

Hopper assembly ................................................................................. 10

Electrical Connection .................................................................................... 11

Operation ........................................................................................... 12

Graphical representation of the controls ................................................... 12

Overview table for the graphic .................................................................... 13

Starting the BB 300 ........................................................................................ 14

Stopping the BB 300 ..................................................................................... 14

Setting the gap width ..................................................................................... 14

Adjusting the zero position of the gap width indicator ........................... 14

Feeding in process material .......................................................................... 15

Notes on working procedures ............................................................ 16

General ............................................................................................................ 16

Input grain size ............................................................................................... 16

Quality of process material .......................................................................... 16

Capacity ........................................................................................................... 16

General ............................................................................................... 17

Cleaning ........................................................................................................... 17

Maintenance .................................................................................................... 17

Tests ................................................................................................................. 17

Replacing crusher jaws .................................................................................. 18

Accessories ...................................................................................................... 18

Modifications .................................................................................................. 18

Safety instructions (table) ............................................................................. 19

Appendix ..................................................................... following pages

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Safety

No liability in any form will be accepted for damage or injury resulting from failure to observe the following notes on safety.

Target group: All persons dealing with the machine in any way

The BB 300 is a modern, powerful product from Retsch GmbH. It reflects the state of the art. When the machine is handled correctly by persons familiar with this technical documentation, it is completely safe and reliable in operation.

Notes on safety

You, as the operator, are responsible for ensuring that the persons appointed to work with the BB 300:

have read and understood all the stipulations of the chapter

on safety,

are familiar before commencing work with all instructions and

regulations for the relevant target group,

have access to the technical documentation for this machine

at all times and without difficulty.

Ensure that new staff have been familiarised with the rules for safe and proper handling before commencing work on BB 300 either by oral instruction by a competent person and/or by this documentation.

Incorrect operation can lead to damage or injury. You are responsible for your own safety and that of your staff.

Ensure that no unauthorised persons have access to the BB 300.

For your own protection, have your staff confirm that they have been instructed in operation of the BB 300. A draft of an appropriate form can be found at the end of the chapter on safety.

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Warning symbols

Personal injury Damage to property

The Retsch agency in your country

Your supplier

Retsch GmbH direct

_____________________________

We use the following symbols to warn of:

Repairs

These operating instructions do not contain any instructions on repairs. For your own safety, only have repairs performed by Retsch GmbH or an authorised agent (service technicians).

In such a case, please inform:

Your service address:

Confirmation

I have read and understood the foreword and the chapter on safety.

__________________________________________________

Signature of the operator

__________________________________________________

Signature of service technician

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Technical data

Do not modify the machine in any way, and use only spare parts and accessories approved by Retsch.

The conformity with European Directives declared by Retsch will otherwise be invalidated.

Furthermore, this will lead to all warranty claims being rendered null and void.

Target group: Owners, operators

Machine type designation: BB 300

Use for the intended purpose

This machine is not designed as a production machine or for continuous operation, but as a laboratory machine intended for 8 hour single shift operation. The BB 300 is suitable for crushing of medium to extremely hard substances and brittle and hard/tough materials. The achievable final fineness can be up to 5 mm and less, depending on the input material. The maximum input grain size is <130 mm. The materials which can be crushed in the BB 300 include the following: concrete // ores // rock // glass // ceramics // coal // minerals // slags // cement clinker etc. Should you require any further details, the Retsch applications laboratory will be pleased to assist.

Gap adjustment

From 1 mm to approx. 40 mm by means of a spindle.

Throughput, final fineness

The performance data, throughput and achievable final fineness are dependent on the breakage behaviour and hardness of the process material and on the gap width set. They can only be determined empirically.

Degree of protection

IP55

Rated power

3000 watts

Noise data

Noise measurement to DIN 45635-31-01-KL3 The noise levels are also decisively influenced by the properties of the material to be ground.

Example 1 :

Sound power level LWA = 95.7 dB(A) Workplace related emission level L

Service conditions :

Input material: Marble pebbles, grain size <90 mm Gap width set: < 1 mm Final grain size: < 14 mm Filling of milling chamber: approx. 65%

= 81.5 dB(A)

p eq

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Example 2:

Height: approx. 1450 mm

Width: approx. 670 mm

Depth: approx. 1600 mm

Weight: approx. 700 kg net

Sound power level LWA = 102 dB(A) Workplace related emission level L

= 90 dB(A)

p eq

Service conditions:

Input material: Quartz pebbles, grain size <55 mm Gap width set: < 1 mm Final grain size: < 10 mm Filling of milling chamber: approx. 65%

Equipment dimensions

Mounting surface required

670 mm x 1600 mm; no safety clearances necessary!

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Dimensional chart

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Transport and installation

Please keep the packaging for the duration of the guarantee period, as your guarantee claim will be endangered in the case of a complaint or return of the machine in inadequate packaging.

The BB 300 must not be thrown, subjected to impact or shock during transport. The electrical and mechanical components may otherwise be damaged.

Fig.1

In order to handle the BB 300 by crane with a minimum load capacity of 1000kp, the feed hopper has been dismantled. The BB 300 can then be handled using appropriate lifting gear. One option is shown in Fig. 1.

Please loop the ropes around both bearing housings on the BB

300. Fig. 1

Interim storage

Also ensure that the BB 300 is stored in a dry location for interim periods.

When there are severe temperature fluctuations (e.g. during air transport) the BB 300 is to be protected from condensation. The electrical components may otherwise be damaged.

Target group: Owners, carriers, operators

Packaging

The packaging is suitable for the mode of transport selected. It complies with the general packaging regulations.

Transport

Temperature fluctuations

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Parameters for the installation location

If the ambient temperature falls below or exceeds the limits specified, the electrical and mechanical components may be damaged or the performance data changed to an unknown extent.

At higher humidity, the electrical and mechanical components may be damaged and performance data changed to an unknown extent.

Fig.2

Fig.2a

A mounting surface of 670mm in width and 1600mm in depth is required. The mouth of the feed hopper is at a height of approx. 1450 mm. Install the BB 300 on an even, firm surface only. Anchoring is not absolutely necessary, as the free mass momentums induce only hardly perceptible vibrations in the vicinity. It can however be effected using the bores in the feet. Fig.2

Hopper assembly In order to ensure safe transport, the BB 300 is delivered with the feed hopper dismantled. A cover is fitted in place of the hopper to prevent inadvertent reaching into the machine. Fig.2a

Remove the eight hexagon screws SK with a 13 mm AF spanner.

Remove plate PL.

Fit the feed hopper.

Insert the eight hexagon screws SK and tighten them well with a

13 mm AF spanner.

Operation of the BB 300 without the feed hopper fitted is impermissible.

Risk of crushing fingers and hands!

Ambient temperature:

5°C to 40°C

Humidity:

Maximum relative humidity 80% at temperatures up to 31°C, decreasing in a straight line to 50% relative humidity at 40°C.

Site altitude:

max. 2000 m above sea level

Installation

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Electrical Connection

The electrical connection must be established by a specialist electrician.

Consult the type plate for the voltage and frequency of the BB

300.

Ensure that the values are in agreement with the mains power

supply.

Connect the BB 300 to the mains using the cable supplied.

Ensure that there is an external fuse in accordance with the local regulations when connecting the unit to the mains supply.

Failure to observe the values on the type plate can result in damage to electronic or mechanical components.

Prior to initial start-up, check the direction of rotation. See the direction arrow on the motor.

If the direction of rotation is incorrect, crushing performance is inadequate and mechanical components can be damaged.

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Operation

Target group: Operators

Controls and operation

Graphical representation of the controls

Fig.3

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Overview table for the graphic

Control

Description

Function

ON/OFF and motor protection switch

Starts and stops the jaw crusher motor, interrupts the power supply when the motor is overloaded.

Feed hopper

Facilitates material feed, prevents inadvertent reaching into the crusher chamber, prevents ejection of process material.

Chamber for a collecting bin

A collecting bin with external dimensions: height = 280mm//width = 450mm//depth = 650mm can be inserted here.

A collecting bin on rollers, V= 50l, is available as an accessory.

Door

Open = collecting bin can be inserted, BB 300 cannot be started. Closed = BB 300 can be started, inadvertent reaching into the machine is impossible.

Door catch

Prevents the door from opening of its own accord.

Limit switch

Stops the motor when the door is open.

Clamp

Fastens the crusher jaws K to the crusher arms Q and P.

Cheese head screw

Fastens clamp G

Crusher jaw

Pulverisation tool

Pointer

Indicates the gap width in conjunction with scale M, pitch

2.5 mm.

Scale

Indicates the gap width in conjunction with pointer L, adjusts the zero position of the gap width when the jaws are worn.

Lock nut

Locks the spindle O for gap width adjustment.

Spindle

Increases the gap width when turned anti-clockwise, reduces the gap width when turned clockwise.

Wear plates

Prevent wear on the side parts.

Fixed crusher arm

Accommodates crusher jaw K, facilitates adjustment of gap width with spindle O.

Moving crusher arm

Accommodates crusher jaw K, performs the necessary crushing motion.

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Starting the BB 300

The BB 300 may only be started with the crusher chamber empty. Process material fed into the crusher chamber or feed hopper before starting leads to blockages, and mechanical components may be damaged.

Fig.4

The ON/OFF switch is located on the front right of the BB 300. Fig.4

Turn the switch to the ON position.

The motor is started, and the moving crusher arm starts to move.

The crushing process can only be started when the door is closed and locked.

When the door is opened, a limit switch prevents the BB 300 from starting.

The ON/OFF and motor protection switch is located on the front right of the BB 300. Fig.2

Turn the switch to the OFF position.

The motor is disconnected from the power supply and the moving crusher arm stops.

Only stop the BB 300 when there is no further process material in the crusher chamber. Mechanical components can be damaged if there is blockage.

Fig.5

Start the BB 300 (under no load). Release lock nut N (anti-clockwise). Turning spindle O clockwise reduces the gap. Turning spindle O anti-clockwise increases the gap. Pointer L roughly shows the gap on scale M, pitch 2.5 mm. Re-tighten lock nut N (clockwise)

Adjusting the zero position of the gap width indicator

Fig.5

Start the BB 300 (under no load). Release lock nut N (anti-clockwise). Carefully turn spindle O inwards (clockwise) until the two crusher

arms just audibly meet.

Release the hexagon or knurled head screws S1 with an 8 mm AF

spanner.

Slide the “0” position on scale M to the zero position of pointer L. Re-tighten the hexagon or knurled head screws S1.

Stopping the BB 300

Setting the gap width

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Do not set the gap width of the BB 300 to below 1 mm. Mechanical components can be damaged if there is blockage.

Fig.6

The feed hopper B can accept process material with grain sizes up to 130 mm. Only fill the feed hopper and the crusher chamber when the machine is running.

The feed hopper is not however intended for storage of process material: its function is solely that of feeding material into the crusher chamber. It also prevents inadvertent reaching into the crusher chamber, and stops process material from being ejected.

Fig.6

If the crusher chamber W is filled more than 2/3 (3500ml), the guide plates on the feed hopper can be damaged and process material conveyed by the moving crusher arm into the crusher casing behind the crusher arm.

Feeding in process material

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Notes on working procedures

Fig.7

The quantity of material in the machine also influences the proportion of fines in the pre-pulverised sample material. The more material in the crusher chamber, the higher the proportion of fines can be.

Target group: Laboratory technicians

General

The BB 300 is a robust free-standing machine which can predominantly be used for preliminary pulverisation of hard or brittle materials. The performance data, throughput and achievable final fineness are dependent on the breakage behaviour and hardness of the process material, and on the gap width set.

Input grain size

The maximum input grain size is determined by the size of the intake opening, and is max. 130 mm on the BB 300.

Quality of process material

In principle, any hard and brittle process material with a Mohs hardness >3 can be crushed in the BB 300. Moist or greasy process material with a Mohs hardness <3 tends merely to compact or cake in the crusher chamber as a result of the pressure applied by the crusher jaws. Crushing is hardly possible in such cases.

Capacity

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General

The feed hopper may only be dismantled by trained specialists, by removing the eight hexagon screws, for cleaning purposes. Operation of the BB 300 with the feed hopper removed is impermissible. Risk of crushing fingers and hands!

Do not clean the BB 300 with running water.

Lethal hazard of electric shock

Solvents must not be used, as the felt seals on the sides of the crusher arms would be destroyed, and grease packing washed out.

Fig.8

The BB 300 requires relubrication from time to time. Fig.8 Please consult the table below for quantities of lubricant and intervals. The positions of the lubrication points are marked by red arrows on the machine.

No. Quantity in kg Interval in operating hours 1 0.025 50 2 0.005 50 3 0.003 500 4 0.005 500

Points not shown in Fig.8 but marked with arrows are permanently lubricated.

Please use the grease gun supplied with the BB 300 for lubrication. As the lubricant, a conventional multipurpose grease can be used, e.g. EP 4685 from ESSO/SHELL or BP.

Fig.9

The function of the limit switch on the door is to be tested every six months. Fig.9

Start the BB 300.

Open catch E.

Open door D until the gap on the left is 50 mm.

Limit switch E must operate, and the BB 300 stop.

If the limit switch does not operate, it requires resetting as described below, or otherwise

Close door D and catch E.

The BB 300 must not start.

Start the BB 300 at main switch A.

Cleaning

Cleaning of the BB 300 is best effected with an industrial vacuum cleaner and a robust, long-handled brush.

Maintenance

Tests

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Notes on setting the limit switch

Fig.10

Remove screws S1. Remove cover A1. Release screws S2, but do not remove them. Move the bracket with limit switch E.

The limit switch must operate as soon as the door is opened by max. 50 mm. Fig.9

Re-tighten screws S2. Fit cover A1 and fasten with screws S1.

Perform the test as described above under “Tests”

Fig.10

Disconnect the mains plug. Remove the feed hopper. Set the gap width to maximum. Remove cheese head screws S3. Remove clamps K1. Replace crusher jaws B1.

Should it prove difficult to remove the clamps, they can be prised off with a screwdriver. Proceed as follows:

Remove plug ST. Insert the screwdriver through the bore which is now free. Tap lightly on the screwdriver with a plastic mallet.

After replacing the crusher jaws, always remember to re-tighten cheese head screws S3 well and refit plugs ST.

Fit the feed hopper and fasten it with the eight hexagon screws.

The feed hopper may only be dismantled by trained specialists, by removing the eight hexagon screws, for cleaning purposes. Operation of the BB 300 with the feed hopper removed is impermissible.

Risk of crushing fingers and hands!

Replacing crusher jaws

Accessories

Collecting bin on rollers, V=50 litres

This documentation may only be duplicated or passed on to third parties,

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its contents passed on or otherwise used with the express approval of Retsch GmbH. Violators will be liable for damages.

Modifications

We reserve the right to make technical modifications without notice.

Safety instructions (table)

for the BB 300 taken from the chapters

Procedure

Action

Dangers

Safety

Not paying attention to the safety instructions can lead to damage to people and property.

Claims for damage are excluded in whatever form.

Packaging

Please retain the packaging for the duration of the guarantee period.

In the case of complaint your warrantee rights can be endangered if the item is returned insufficiently packaged

Transport

During transportation the BB 300 should not be knocked, shaken or thrown.

Electronic and mechanical components can become damaged.

Temperature variations

With severe variations in temperature, the BB 300 must be protected from condensation.

Electronic components can become damaged.

Scope of delivery

In the case of the delivery being incomplete and/or transport damage, you must inform the carrier and Retsch GmbH immediately (within 24 h).

Later complaints can under certain circumstances no longer be considered.

Environmental temperature

Drops below 5°C Rises above 40°C

Electronic and mechanical components can become damaged. Performance data change by an unknown extent.

Air humidity

Rises above 80% at temperatures up to 31%

Electronic and mechanical components can become damaged. Performance data change by an unknown extent.

Mounting the hopper

In order to be sure to be able to guarantee the transport, the BB 300 has been delivered with a dismounted filling hopper. It is not permissible to run the BB 300 without a filling hopper mounted.

Danger of crushing for fingers and hands.

Electrical connection

Mains supply does not match the values given on the type plate. Before initial operation, the direction of rotation is to be checked, see rotation direction arrow on the motor.

Electronic components can become damaged.

If the direction of rotation is wrong, no satisfactory milling will take place and mechanical components can become damaged.

Operation

During starting, stopping and disconnection, there must be no material for grinding in the crushing chamber or in the feed hopper.

Mechanical components can possibly become damaged via a blockage.

Do not set gap width below 1 mm.

Mechanical components can possibly become damaged via a blockage.

The crushing chamber is not be filled by more than 2/3.

Otherwise the guide plates of the feed hopper can becoming damaged and the material for grinding will be delivered by the breaking arm into the crusher housing behind the arm.

Cleaning

Each time before cleaning, pull out the mains plug.

Danger of death by electrocution.

Do not clean with running water.

Danger of death by electrocution.

Solvents are not permitted.

Since they would damage the felt seals on the sides of the breaking arms or wash out the grease filling.

The filling hopper may be swung back for cleaning, by unscrewing the two socket screws, only by assigned, trained personnel. Operation of the BB 300 without screwed-in socket screws and without the filling hopper is not permitted.

Danger of crushing for fingers and hands.

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Authorized person for the compilation of technical documents:

J. Bunke (technical documentation)

The following records are held by Retsch GmbH in the form of Technical Documentation:

Detailed records of engineering development, construction plans, study (analysis) of the measures required for conformity assurance, analysis of the residual risks involved and operating instructions in due form according to the approved regulations for preparation of user information data.

The CE-conformity of the Retsch Jaw Crusher Type BB 300 is assured herewith.

In case of a modification to the machine not previously agreed with us as well as the use of not licensed spare parts and accessories this certificate will lose its validity.

Retsch GmbH Haan, January 2010

Dr. Stefan Mähler Manager technical services

R e t s c h G m b H R e t s c h - A l l e e 1 - 5 4 2 7 8 1 H a a n G e r m a n y w w w . r e t s c h . c o m

JAW CRUSHER

BB 300

FB-EW-805-028 (E) Änderungsstand F 01.2012

CERTIFICATE OF CE-CONFORMITY

Translation

Certificate of CE-Conformity according to:

EC Mechanical Engineering Directive 2006/42/EC

Applied harmonized standards, in particular: DIN EN ISO 12100 Security of machines

EC Directive Electromagnetic Compatibility 2004/108/EC

Applied standards, in particular:

DIN EN 50081 Generic standard interference emission - living areas - in conjunction with

EN 55022 and EN 60555

DIN EN 50082 Generic standard interference resistance - living areas

Additional applied standards, in particular

DIN EN 61010 Safety prescriptions concerning measuring-, operating-, controlling- and

laboratory equipment

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

Retsch BB 300 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual