Operating Instructions for the
Disk Mill Model DM200
Retsch GmbH, 42781 Haan, Retsch-Allee 1-5, Germany, 2/8/2012 0002
Information on these Operating
Instructions
The present operating instructions for the laboratory
model DM200 disk mill provides you with all of the
necessary information on the areas specified in the
table of contents.
It is an instruction for the target group(s) defined for
each of these areas in the safe and intended use of
the DM200. The prerequisite of each of the target
group(s) being able to use it safely and as intended is
having a knowledge of the relevant sections.
The present technical documentation is a reference
work and instructions for learning and each of the sections is closed in and of itself.
These operating instructions are not instructions for
repair. If repairs should be necessary, please consult
your vendor or get in contact with Retsch GmbH directly.
16.11.2006 Retsch GmbH 2 Doc.Nr. GB 98.740.9999
Information on these Operating Instructions
.................................................................... 2
Safety .......................................................... 4
Safety Information ..................................... 4
Warning Signs ........................................... 4
Repairs ..................................................... 5
Confirmation ............................................. 5
Technical Data ............................................. 6
Use as intended ......................................... 6
Functional Description ................................ 6
Protective Equipment ................................. 7
Drive ........................................................ 7
Motor Output ............................................ 7
Rated Voltages .......................................... 7
Rpm's ...................................................... 7
Protective Types ........................................ 7
Emissions ................................................. 8
Machine Dimensions ................................... 8
Floor Space Required ................................. 8
Transportation and Installation ................... 9
Packaging ................................................. 9
Transportation ........................................... 9
Intermediate Storage ................................. 9
The Parameters for the Place of Installation .. 10
Installation................................................ 10
Electrical Connection .................................. 10
Operation ..................................................... 11
The Operating Elements and Operation ......... 11
Adjusting the Gap Width ............................. 12
Starting the Machine .................................. 12
Feeding the Material to be Crushed .............. 12
Changing the direction of
rotation, replacing the milling disks .............. 13
General Information .................................... 15
Accessories ............................................... 15
Cleaning ................................................... 15
Service ..................................................... 15
Necessary Safety Tests............................... 15
Copyright .................................................. 15
Modifications ............................................. 15
Safety Regulations (Table) .......................... 16
Appendix .............................. following pages
16.11.2006 Retsch GmbH 3 Doc.Nr. GB 98.740.9999
Safety
We will not be liable for any claims to compensation
whatsoever for property damage or personal injury
that were caused by not observing the following safety
information.
!
personal injury
property damage
The DM200 laboratory disk mill is a highly modern
high-performance product from Retsch GmbH and is
state-of-the-art. If the machine is used as intended
and if the user has a knowledge of the technical
documentation here, it is completely safe when operated.
Safety Information
You as the operator have to ensure that the persons
entrusted with working at the DM200:
have taken notice of and understood all of the
regulations in the area of safety,
know all of the instructions for use and regula-
tions of the target group relevant for them before commencing work,
have access to the technical documentation of
this machine at any time and without any problems.
Before work is commenced on the DM200, ensure
that new personnel has been made familiar with its
safe and intended use either by having a competent
person introduce it to them orally and / or based upon
the present technical documentation.
Improper operation may lead to personal injury, property damage or injury. You are responsible for your
own safety and that of your employees.
Ensure that no unauthorised persons have access to
the DM200 laboratory disk mill.
For your own protection, have your employees confirm
that they have been instructed in the operation of the
DM200. You will find the draft of the appropriate form
after the section on safety.
Warning Signs
we give warnings with the following signs:
16.11.2006 Retsch GmbH 4 Doc.Nr. GB 98.740.9999
Repairs
The Retsch agency in your country
your vendor
Retsch GmbH directly
These operating instructions are not instructions for
repair. For your own safety, repairs may only be done
by Retsch GmbH or an authorised agency or service
technicians.
In this case, please notify:
your service address:
Confirmation
I have taken notice of the foreword and the section on
safety.
_______________________________________
________
the signature of the operators
_______________________________________
________
the signature of the service technician
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Technical Data
!
The DM200 is not designed to be explosion protected and therefore it is not suited to milling explosive self-igniting or fire-promoting substances.
!
If oxidised materials are milled such as metals,
organic materials, wood, plastics, etc., there is the
danger of self-ignition (dust explosion) if the proportion of fines exceeds a certain percentage. It is
necessary to observe the appropriate safety
guidelines when materials such as these are
crushed.
Do not modify the machine and only use the spare
parts and accessories approved by Retsch.
Otherwise the conformity with European directives declared by Retsch shall be rendered
invalid.
Furthermore, this leads to a loss of all warranty claims.
The material sample is crushed by two milling
discs coarsely meshed on the inside working
against one another in a milling space sealed
against dust from the outside. One of these is
driven by a powerful and slow moving gear motor.
The material to be milled is filled into the centre
of the stationary milling disc through a closable
funnel and it escapes from the gap between the
two disks after being crushed by compressing and
shearing force. The width of the gap can be adjusted and controlled from outside and determines
the mean granulation of the material to be milled.
machine model designation: DM200
Use as intended
The DM200 laboratory disk mill is suited for finely
milling soft to hard materials (up to 8 Mohs) in sets or
continuously from the fields of mining and metallurgy,
rocks and earth, the glass industry or soil research.
Our applications laboratory would be glad to give you
further information upon request.
The DM200 is designed for quantities from 20 to approximately 150 Kg/h depending upon the setting of
the discharge gap and the piled density and crushing
behaviour of the sample. The feed size may not exceed an edge length of a maximum of 20 mm.
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Functional Description
Protective Equipment
The following safety equipment reliably prevents persons
from unintentionally putting their hands in the machine
when it is running.
funnel tube designed in conformity with EN 294.
This prevents persons from putting their hands into
the milling space when the flap is opened
safety limit switch.
This prevents the machine from starting up when the
milling space is open.
It also stops the motor within a safe period of time
when the milling space is opened during operation
safety limit switch.
This prevents the machine from starting up when the
collecting container is drawn out.
It also stops the motor within a safe period of time
when drawing out the collecting container.
protective motor switch, ON/OFF switch.
This switches off the machine automatically if there is
a defect or if the motor is overloaded.
position [ I ] the machine starts.
position [ 0 ] the machine stops.
This prevents the machine from starting up independently if there is an electrical defect or power failure.
3~ 230 V
50 /
60Hz
approx. 5.7 A
3/N~ 400 V
50 /
60Hz
approx. 3.3 A
3~115 V
50 /
60Hz
approx. 11.4
A
3~ 200 V
50 /
60Hz
approx. 6.5 A
gear motor
IP 55
safety limit switch for the door
IP 67
safety limit switch for the collecting
container
IP 67
protective motor switch, ON-OFF
switch
IP 55
Drive
standard three-phase gear motor
Motor Output
1,500 Watt
Rated Voltages
Rpm's
50Hz = Rpm's 440 min-1
60Hz = Rpm's 528 min-1
Protective Types
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Emissions
Characteristic Noise Values :
Noise measurement in conformity with DIN 45635031-01-KL3
The properties of the material to be crushed also has
an effect upon the characteristic noise values.
sound level LWA = 81 dB(A)
emission read at the workpiece L
= 69,4 dB(A)
pAeq
Machine Dimensions
height: 400 mm, 500 mm with the vertical flap on
the funnel.
width: 430 mm, 900 mm with door opened at 180°.
depth : 890 mm, 1,000 mm with door opened at 90°
weight: approximately 140 kg
Floor Space Required
430 mm x 1000 mm; a safety distance is not necessary.
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Transportation and Installation
Please store the packaging for the duration of the
warranty period because your warranty claim
would be endangered if there were a complaint
and it were returned in insufficient packaging.
In order to be able to transport the DM200 in a
crane of a minimum load-bearing capacity of 250
kp, it should be hoisted with the hoisting equipment as shown in the adjacent figure.
The DM200 may not be shocked, shaken or
thrown during transportation. Otherwise, the electronic and mechanical component parts could be
damaged.
If there are strong temperature fluctuations (for
instance, when being transported by aeroplane),
the DM200 should be protected from condensation
water. Otherwise, there could be damage to the
electronic component parts.
Packaging
Packaging is in accordance with the transportation
path and satisfies the generally recognised packaging
guidelines.
Transportation
Temperature Fluctuations
Intermediate Storage
Please also ensure that the DM200 is stored dry if it is
placed in intermediate storage.
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The Parameters for the Place of Installation
If the temperature is above or below the ambient
temperature, the electronic and mechanical component parts may be damaged changing the performance data in an unpredictable fashion.
If the humidity is higher, the electronic and mechanical component parts may be damaged changing
the performance data in an unpredictable fashion.
Only place the DM200 on a solid and sturdy foundation.
Electrical and mechanical component parts may be
damaged if the values on the nameplate are not
complied with.
!
Modifications or rebuilding it to a supply voltage
other than stated on the machine nameplate should
only be done by an electrician.
Danger of Current Surge!
ambient temperature :
5°C to 40°C
humidity :
The maximum relative humidity is 80% at temperatures up to and including 31°C, decreasing linearly to
50% relative humidity at 40°C
Installation Altitude:
a maximum of 2,000 m above sea level
Installation
Electrical Connection
The mains fusing should be designed as follows:
at 3~ 230 and 3/N~ 400V = 16A
at 3~ 115 and 3~ 200V = 20A
you may find the voltage and frequency of the
DM200 on the nameplate.
please ensure that the values agree with the ex-
isting power mains.
only connect the DM200 to the power mains with
the aid of the cable connector supplied.
You may have the connection made directly with a
change-over switch to avoid having to call in an electrician. This has the benefit that the milling disc teeth
may be used by both sides. This is described in the
section "Changing the Direction of Rotation and
Replacing the Milling Disc".
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Operation
A B C D E F G H I J K
C L D H J K
item
element
function
A
door
seals the milling space dustproof
B
funnel tube
receives the material to be milled
C
window milling gap
enables you to check the milling gap by means of blade gauge
D
collecting container
receives the crushed material to be milled
E
milling disc doors
crushes the material to be milled fed into it together with F
F
milling disc housing
crushes the material to be milled fed into it together with E
G
safety switch for the door
prevents the machine from starting up when the door is open
H
lubrication point
enables you to relubricate the coupling
I
door lock
enables you to open and safely close the doors
J
protective motor switch
disconnect the motor from the mains if there is an overload
position [I] the machine is switched on
position [0] the machine is stopped
K
gap adjustment crank
enables you to adjust the gap together with C
graduation line = 0.01 mm
L
safety switch for the collecting container
prevents the machine from starting up when the collecting
container is drawn out
The Operating Elements and Operation
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Adjusting the Gap Width
You may adjust the gap width between the milling disc in
the housing and in the door just by adjusting the graduated rotating crank mounted below the motor. 1 graduation line = 0.01 mm.
You may adjust the gap from 0.1 to approximately 5 mm.
Rotating Crank
Caution! Do not go below the minimum gap width of 0.1
mm.
You may control check the gap width setting through a
window behind the funnel tube by means of a sensing
gauge.
Window
You may also adjust the gap width when the machine is
running.
Material that is difficult to mill should be milled at least
twice. Select a larger gap width as pre-crushing for the
first pass and then you achieve the desired final fineness
with the small gap in the second milling pass.
Caution !
The smallest gap width is 0.1 mm.
The milling discs may not touch one another because otherwise
this could damage the milling discs.
It is only possible to start the DM200 when the door is
closed and the collecting container has been inserted.
The ON-OFF switch is on the right-hand side of the
DM200.
ON-OFF switch
position [I] DM200 starts
position [0] DM200 stops
The ON-OFF switch also acts as a protective motor
switch.
If the motor is overloaded or if there is another electrical
fault, this switch disconnects the DM200 from the mains.
The DM200 can only start up when the DM200 is
manually started with the ON-OFF switch.
After the gap has been set and the DM200 has been
started, you commence material feed. Do not exceed a
maximum edge length 20 mm. Open the lid of the funnel
tube for this purpose.
the lid of the funnel tube
When feeding the material to be crushed, please ensure
that the funnel tube lid is closed because otherwise the
material to be crushed could fall back.
Furthermore, the quantity of fed material to be crushed
depends upon its millability. Therefore, note the decreasing intensity of the milling sound to ascertain the optimum feed quantity.
Caution!
Only feed the material to be crushed after having started the
DM200.
If the DM200 starts up filled with material to be crushed, this
may lead to damage in the mechanical component parts.
Starting the Machine
Feeding the Material to be Crushed
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Changing the direction of rotation, re-
The milling disks are subject to natural wear after use over
a long period.
However, before they need to be replaced by new ones the
direction of rotation of the motor can be changed so that
the opposite side of the gear teeth can be used. By this
means the service life of the milling disks can be extended.
Changing the direction of rotation:
By reversing the phases of the mains supply the direction of
rotation of the motor can be changed. Since this necessitates intervention in the electrical connecting line of the
DM200 the change in direction of rotation should be carried
out only by a qualified electrician.
However, it is possible to install a direction of rotation
change-over switch when connecting up to the mains supply
for the first time. It is then no longer necessary for an electrician to intervene when the the direction of rotation has to
be changed again.
Replacing the milling disk in the door:
Disconnect the mains plug
Remove the collecting vessel
Keep the door closed
Slightly unscrew the hexagon bolts or hexagon nuts with
an open-jawed spanner
Open the door
Keep a firm hold on the milling disk while unscrewing
both hexagon bolts with washers
Remove the milling disk
Clean the mounting of the milling disk in the door
Insert a new milling disk so that its contact surface is
level
Screw in the hexagon bolts again – for zirconium oxide
hexagon nuts are used
placing the milling disks
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Replacing the milling disk in the housing:
Disconnect the mains plug
Remove the collecting vessel
Open the door
Lift up the cover
Unscrew the hexagon bolts or hexagon nuts with an SW
30 open-jawed spanner
Remove the milling disk
Clean the mounting of the milling disk
Place a new milling disk in position
The milling disk must have a level contact surface
Screw in the hexagon bolts with washers – for zirconium
oxide hexagon nuts are used.
GS SS
Caution
It is essential that the milling disks have a level contact
surface.
There should be no unevenness or other components under
the milling disk.
For zirconium oxide disks it is absolutely necessary that the
rubber washer GS is placed under the steel washer SS.
Caution
Milling disks of zirconium oxide should be tightened with a
torque of only 20-30 Nm. Do not forget the rubber washer
GS.
Milling disks of steel and tungsten carbide are tightened
with a torque of 50-100 Nm.
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General Information
!
Do not clean the DM200 with flowing water.
Danger from Current Surge
Only use moistened rags.
Solvents are not permitted.
The protection type of DM200 is IP 55
The DM200 does not require service, although it should
be relubricated on the lubricating nipple of the shifting
sled.
Conventional lubricating grease may be used for this
purpose.
A grease gun is also available as an accessory under
the order no. 05.185.0006.
!
If the machine is not functioning properly, do not continue to operate it and get in contact with our customer
service.
Accessories
Cleaning
You may pull out the collecting container for cleaning purposes.
Open the door to clean the milling discs, the milling space
and the funnel tube.
You may now conveniently clean the entire area that has
come into contact with the material to be crushed with the
aid of a brush or vacuum cleaner.
Service
Necessary Safety Tests
The safety limit switches on the door and the collecting
container should be checked on a monthly basis to see if
they are in perfect working order:
open the door:
It may not be possible to switch on the DM200 any more
with the ON/OFF switch.
close the door:
It must be possible to start the DM200 with the ON/OFF
switch again.
pull out the collecting container:
It may not be possible to switch on the DM200 any more
with the ON/OFF switch.
push in the collecting container:
It must be possible to start the DM200 with the ON/OFF
switch again.
Copyright
It is only allowed to pass on or copy this documentation
or utilise and pass on its content with the express permission of Retsch GmbH.
Non-compliance engages the obligation of compensa-
16.11.2006 Retsch GmbH 15 Doc.Nr. GB 98.740.9999
tion for damage.
Modifications
We reserve the right to make technical modifications.
Safety Regulations (Table)
for the DM200 from the sections
process
action
hazards
safety information
property damage and personal
injury may be incurred if the safety
information is not observed.
no claims to compensation for damage
shall be accepted whatsoever
intended use
do not mill any explosive selfigniting or fire-promoting materials
danger to life and limb because of
explosion because the DM200 is not
designed to be explosion protected.
do not mill materials whose fine
proportion at a certain percentage
may lead to an explosion.
danger to life and limb because of
explosion because the DM200 is not
designed to be explosion protected.
do not modify the machine and
only use the spare parts and accessories approved by Retsch.
otherwise the conformity with European directives declared by Retsch
shall be rendered invalid.
Furthermore, this leads to the loss of
all warranty claims.
packaging
please store the packaging for the
warranty period.
if there is a complaint and it is returned in insufficient packaging, this
may jeopardise your warranty claims.
temperature fluctuations
protect the DM200 from condensate water forming if there are
temperature fluctuations.
electronic component parts may be
damaged.
transportation
do not shock, shake or throw the
DM200 during transportation
electronic and mechanical component
parts may be damaged.
scope of delivery
if the delivery is incomplete and /
or if there is damage from transportation, you have to inform the
transporter and Retsch GmbH
without delay (within 24h).
under certain circumstances later
complaints may not be recognised.
ambient temperature
should not fall below 5°C
should not go above 40°C
electronic and mechanical component
parts may be damaged and performance data may change unpredictably.
humidity
do not exceed a relative humidity
of 80% at 31°C or 50% (descending linearly) at 40°C.
higher humidity may damage the electronic and mechanical component
parts and performance data may
change unpredictably.
electrical connection
the network does not agree with
the values on the nameplate.
electronic and mechanical component
parts may be damaged.
adjusting the gap
width
do not adjust a gap width < 0.1
mm
if the milling discs come into contact
with one another, they may be damaged.
feeding the material
to be crushed
only feed material to be crushed
when the DM200 is operating.
if the DM200 starts up filled with material to be crushed, this may damage
the mechanical component parts.
cleaning
do not clean the DM200 with flowing water.
danger from current surge.
the protection type of the DM200 is
IP55
safety tests
get in contact with customer service if the safety equipment functions improperly..
if defects are improperly repaired, this
may lead to danger to life and limb.
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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.
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 er m a n y w w w . r e t s c h . c o m
DISC MILL
DM 200
FB-EW-805-042 (E) Änderungsstand D 01.2012
CERTIFICATE OF CE-CONFORMITY
Translation
THIS MACHINE CONFORMS TO THE FOLLOWING STANDARD SPECIFICATIONS AND DIRECTIVES:
The EC Directive for Machines „Directive 89/392/EEC“, Appendix 1, Subsection 1 Fundamental Safety and
Health Requirements for Machine Design and Construction,
The EC Directive for Electromagnetic Compatibility (EMC) „Directive 89/336/EEC (May 3, 1989) of the
Council for Alignment of the Laws of the Member States for Electromagnetic Compatibility“ (including modifi-
cations till July 22, 1993),
The Requirements on „ Electrical Equipment of Machines“ (IEC 204-1 1992, modified)
German Version EN 60 204-1 : 1992.
In case of a modification to the machine not previously discussed with us as well as the use of not
licensed spare parts and accessories this certificate will lose its validity.
We affirm herewith that the certification process was conducted exclusively in accordance with Directive
89/392/EEC (Jun. 14, 1989), Amendment 91/368/EEC (Jun. 20, 1991),, Modification 93/44/EEC (Jun. 14,
1993), Modification 93/68/EEC (July 22, 1993), Directive of the Council for Alignment of the Laws of the
Member States for Machines.
Copyright
® Copyright by
Retsch GmbH
Haan, Retsch-Allee 1-5
D-42781 Haan
Federal Republic of Germany
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