service sm2000 en

Repair Manual for Cutter Mill type SM 2000

©Retsch GmbH & Co.KG , 42781 Haan , Rheinische Str.36 , GermanyDoc. No. GB 98.721.9998

1. Rectification of malfuctions (troubleshooting)................... 3

2. Description of repairs ................................................... 3

3. Replacing the fuses on the controller .............................. 3

4. Replacing the safety door catch ..................................... 4

5. Replacing the motor..................................................... 4

6. Replacing the controller with operator control .................. 5

7. Replacing the grooved ball bearing with conical sleeve ...... 5

8. Replacing the indexable inserts...................................... 6

9. Replacing the cutter bars .............................................. 6

10. Replacement and setting of the tensioning pins .............. 6

11. Replacing the rotor and the felt washer ......................... 7

12. Technical data ........................................................... 8

Parts list, Section 1.......................................................... 9

Parts list, Section 1 (continued)......................................... 10

Teileliste Teil 2 Normteile.................................................. 10

Parts list, Section 3.......................................................... 11

Spare part assemblies...................................................... 11

List of spare parts for 2 years’ operation............................. 12

Recommended stock of spare parts.................................... 12

Dimensional chart for SM2000 with standard hopper ............ 13

Drawings, Part 1 ............................................................. 14

Drawings, Part 2 ............................................................. 15

Drawings, Part 3 ............................................................. 16

Drawings, Part 4 ............................................................. 17

Parts lists and drawings for the accessories......................... 18

Standard hopper ............................................................. 18

Filter unit ....................................................................... 19

Accessory box................................................................. 20

Long material hopper....................................................... 20

Cutter roller with slide...................................................... 21

Circuit diagrams.............................................................. 22

Circuit diagram for 1x220/230V......................................... 22



Circuit diagram for 3x440V ............................................... 25


Circuit diagram for 1x220/230V AE=J................................. 27



Circuit diagram for 3x440V AE=J ....................................... 30

Modifications .................................................................. 31

20.10.2006 Retsch GmbH & Co.KG Doc. No. GB 98.721.9998 2 ©

1. Rectification of malfuctions (troubleshooting) Fault Cause Remedy

LEDs do not light up 1. No power 2. Main switch not ON 3. Fuses on the controller defective 4. Controller defective

1. Check external connection 2. Turn main switch ON 3. Replace fuses –see section 3 4. Replace controller – see

section 6

Motor does not run 5. Thermal relay has tripped 6. Fuses on the controller defective 7. Motor defective

5. Switch the machine off and allow the motor to cool down

6. Replace the fuses – see section 3 7. Replace the motor – see section 5

Door cannot be opened 8. Fuses on the controller defective 9. Safety door catch defective

8. Replace the fuses – see section 3 9. Replace the safety door catch –

see section 4

2. Description of repairs

Note: We recommend you to have the repairs described in sections 4, 6, 7 and10 performed at our works or by the local authorised agent.

3. Replacing the fuses on the controller

Tools required: 1 Phillips screwdriver size 2

Spare parts required: 3x fuses, 1A, slow blow, 6.3x32mm long Retsch Art. no. 05.699.0050

Procedure: • Disconnect the machine from the power supply. • Remove screws 91 from the right hand side panel. • Carefully tilt side panel 1 over. • Replace the fuses. • Assemble by reversing the above procedure.


4. Replacing the safety door catch

Tools required: 1 Phillips screwdriver size 2 1 Allen key, 2.5 mm AF

Spare parts required: 1 x safety door catch Retsch Art. no. 05.656.0001

Procedure: • Disconnect the machine from the power supply. • Remove screws 98 from the right hand side panel 2. • Remove side panel 2. • Remove the fastening screws98 for the safety catch 36. • Carefully draw the safety door catch off. • Detach the wiring connections from the safety door catch. • Replace the safety door catch. • Restore the wiring connections as shown in the circuit

diagram. • Assemble by reversing the above procedure.

5. Replacing the motor

Tools required: 1 Allen key, 8 mm AF 1 Screwdriver, 5 x 80 1 Hexagon socket wrench, 7 mm AF 1 Hexagon socket wrench, 8 mm AF 1 Open jawed spanner, 16/17 mm AF

Spare parts required: 1x motor Retsch Art. no.: See parts list, item 401-419

Procedure: • Open the door and housing top. • Only then disconnect the machine from the power supply. • Remove cheese head screw 84 for the rotor. • Draw off the rotor with cheese head screw M10x130

DIN912. • Open the motor terminal box K. • Release the connecting cable and draw it off the motor • Unscrew the hexagon nuts 88. • Replace the motor. The motor weighs approx. 62kg. • Assemble by reversing the above procedure. • Reconnect the wiring as shown in the circuit diagram. • Ensure that the motor turns in the correct direction:

counter-clockwise. Tightening torque for rotor screw 84 = 14Nm Tightening torque for nuts 88 = 16Nm


6. Replacing the controller with operator control

Tools required: 1 Phillips screwdriver size 2 1 Hexagon socket wrench, 5.5 mm AF

Spare parts required: 1x controller with operator control Retsch Art. no.: See parts list

Procedure: • Disconnect the machine from the power supply. • Remove screws 91 from the right hand side panel 1. • Carefully tilt side panel 1 over. • Remove the ribbon cable from the operator control to the

controller. • Remove the hexagon nuts B on the operator control. • Replace the operator control. • Release the cable connections on the controller. • Unscrew hexagon nuts A on the controller. • Replace the controller. • Restore the cable connections as shown in the circuit

diagram. • Assemble by reversing the above procedure.

7. Replacing the grooved ball bearing with conical sleeve

Tools required: 1 Allen key, 4 mm AF

Spare parts required: 1x grooved ball bearing with conical sleeve Retsch Art. no. 22.363.0001 1x door seal Retsch Art. no. 03.241.0061

Procedure: • Open the door. • Switch the machine off. • Remove the countersunk screws 100. • Remove seal 25. • Use two cheese head screws M4x20 DIN912 to push

washer 15 out. • Press the grooved ball bearing and conical sleeve out. • Lightly oil the outer ring of the ball bearing. • Press the ball bearing in. • Glue in a new seal with Technicoll 8050. • Refit washer 15.


8. Replacing the indexable inserts

Tools required: 1 special key 41 included in the supply

Spare parts required: 18x indexable inserts with screws Retsch Art. no. 05.908.0001

Procedure: • Open the door and housing top. • Switch the machine off at the main switch. • Remove the old indexable inserts. • Fit new indexable inserts. • Tighten the indexable inserts well. (10Nm) • Check the cutting gap: never less than 0.3 mm.

9. Replacing the cutter bars

Tools required: 1 Allen key, 3 mm AF 1 Allen key, 5 mm AF

Spare parts required: 4x cutter bars Retsch Art. no. 03.720.0001

Procedure: • Open the door and housing top. • Switch the machine off. • Remove the central screws 83. • Replace the cutter bars. • Check the cutting gap with a feeler gauge: never less than

0.3 mm. • Adjust the gap if necessary by releasing set screws 86. Tightening torque for screw 83 = 7Nm.

10. Replacement and setting of the tensioning pins

Tools required: 1 Screwdriver, 5 x 80 1 Allen key, 3 mm AF 1 Open jawed spanner, 16/17 mm AF

Spare parts required: 2x tensioning pins Retsch Art. no. 03.657.0001

Procedure: • Open the door and housing top. • Switch the machine off at the main switch. • Release hexagon nut 79 and/or set screw 85 lösen, and

unscrew the tensioning pin. • Fit a new tensioning pin.

See next page for settings.


Settings: Tensioning pin in the housing top • Release set screw 85. • Turn the tensioning pin: clockwise = tighter counter-clockwise = looser

The tensioning pin is correctly set when the housing top is free of play and the handwheel easily engages in the “CLOSED” position.

• Retighten set screw 85.

Tensioning pin in the door • Release hexagon nut 79. • Turn the tensioning pin: clockwise = tighter counter-clockwise = looser

The tensioning pin is correctly set when the housing top is free of play and the handwheel easily engages in the “CLOSED” position.

• Retighten hexagon nut 79.

11. Replacing the rotor and the felt washer

Tools required: 1 Allen key, 3 mm AF 1 Allen key, 6 mm AF 1 Allen key, 8 mm AF 1 Cheese head screw M10x130 DIN912

Spare parts required: 1x rotor Retsch Art. no. 22.608.0005 for 750-835min-1 1x rotor Retsch Art. no. 22.608.0006 for 1430-1690min-1 1x felt washer Retsch Art.Nr. 03.182.0024

Procedure: • Open the door and housing top. • Only then disconnect the machine from the power supply. • Remove cheese head screw 84 for the rotor. • Draw off the rotor with cheese head screw M10x130

DIN912 • Remove countersunk screws 99. • Remove washer 11. • Replace the felt washer. • Assemble by reversing the above procedure. Tightening torque for screw 84 = 14Nm.


12. Technical data

Drive Standard 3-phase motor or single phase AC motor

Mains voltage required see type plate ± 5%

Rated power 1500 Watt

Protection - motor IP 54

Speed of three phase motor 750min-1 at 50Hz - 835min-1 at 60Hz

Speed of AC motor 1430min-1 at 50Hz - 1690min-1 at 60Hz

Activation ⇒ Main switch A ( ON-OFF)

Start ⇒ Sensor key B green

Stop Sensor key C red

Deblocking door and housing Central catch D

Open door Sensor key E blue

Overload protection Temperature sensor in motor

Fuses, external At site supply in accordance with motor current (see type plate on motor) for each phase

Fuses, internal 3x 1A, slow blow, on the controller Art. No. 05.699.00050

Noise level 66 dBA under no load 75-92 dBA when milling, up to 98 dBA

Dimensions 550 x 600 x 1805 mm (w x d x h)

Weight 95-130 kg


Parts list, Section 1 Item Code Qty. Article no. Designation

1 1 03.009.0026 Cover for electronics enclosure 2 1 03.009.0027 Cover for safety door switch 3 1 01.011.0023 Collecting tank, 5 litre 4 1 03.013.0001 Cover disk for handwheel 5 1 03.009.0028 Cover for housing top 6 1 03.042.0214 Pin for door 7 1 03.042.0215 Pin for housing top-bottom 8 2 03.061.0001 Collar for door- housing bottom 9 1 05.106.0012 Cable gland for power cable 10 2 05.106.0023 Cable gland for motor cable 11 1 03.111.0001 Sealing ring for grinding chamber – motor shaft 12 1 03.111.0002 Seal for connector or item 5 13 1 05.112.0027 Reducer for motor terminal box 14 E 1 05.114.0040 O-ring for 5 litre collecting tank 15 E 1 03.143.0037 Insert for door 16 1 03.149.0001 Electronics enclosure 17 1 05.181.0069 Pressure spring for central catch 18 E 1 03.182.0024 Felt washer for motor shaft 19 1 03.183.0012 Flange for collecting tank 20 E 1 03.183.0013 Flange for motor 21 1 03.222.0053 Housing bottom 22 1 03.222.0059 Housing top 23 1 05.225.0016 Handle for door 24 E 2 03.241.0055 Rubber seal for housing top-bottom 25 E 1 03.241.0061 Rubber seal for door 26 1 03.268.0003 Handwheel for central catch 27 E 1 05.274.0001 Main switch 28 E1 1 03.363.0001 Conical sleeve 29 1 03.108.0033 Pressure piece 30 4 03.043.0003 Spacer bushing for operator control 31 4 03.265.0119 Sleeve for centring pin 32 E2/E3 1 03.608.0035 Rotor disk no.1 33 E2/E3 5 03.608.0036 Rotor disk no. 2 – no. 6 34 E1 1 05.617.0018 Grooved ball bearing for door 35 1 03.622.0001 Notched disk for central catch 36 E 1 05.656.0001 Safety catch 220V-50/60Hz 37 E 2 03.657.0001 Tensioning pin for central catch 38 1 03.658.0001 Slotted pin for central catch 39 E 1 05.719.0001 Closing block for safety catch 41 1 05.728.0023 Key for indexable inserts 42 1 03.731.0326 Caution! Mains Plug label 43 1 03.731.0327 OPEN-CLOSE handwheel label 44 1 03.731.0328 OPEN-CLOSE housing label 46 1 01.747.0040 Connector 47 1 03.005.0009 Stop for housing bottom-top 48 1 03.796.0003 Door 49 1 03.798.0009 Keyboard membrane 50 1 03.800.0001 Keyboard mounting 51 1 03.824.0041 Subframe


Parts list, Section 1 (continued) Pos. Code Qty. Article no. Designation

52 2 03.867.0005 Catch hook 54 4 03.937.0001 Centring pin for door – housing top/bottom 55 2 03.112.0069 Spacer ring for door – housing bottom 56 3 05.022.0001 Cap for electronics enclosure cover 59 E2/E3 1 05.728.0015 Allen key for item 5 61 4 05.753.0021 Plug for subframe 62 4 05.005.0006 Foot (stop buffer), subframe 64 1 05.731.0051 Label (arrow) for direction of rotation 65 1 05.727.0041 Cable tie

Teileliste Teil 2 Normteile Item Code Qty. Article no. Designation

70 1 08.935.0002 Straight pin 5m6x10 DIN7 71 2 08.933.0035 Cheese head screw M3x12 DIN84 72 2 08.933.0006 Cheese head screw M4x8 DIN84 73 6 08.701.0012 Washer A3,2 DIN125 75 4 08.701.0018 Washer A6,4 DIN125 76 4 08.701.0001 Washer A8,4 DIN125 77 E2/E3 5 08.181.0001 Spring washer A8 DIN127 78 3 08.181.0007 Spring washer A10 DIN127 79 1 08.642.0018 Hexagon nut BM10 DIN439 80 3 08.221.0025 Set screw M10x35 DIN551 81 E2/E3 4 08.933.0144 Cheese head screw M6x10 DIN6912 82 7 08.933.0016 Cheese head screw M6x16 DIN 912 83 4 08.933.0075 Cheese head screw M6x30 DIN912 84 E2/E3 1 08.933.0139 Cheese head screw M8x90 DIN912 85 3 08.221.0001 Set screw M6x10 DIN914 86 8 08.221.0040 Set screw M6x20 DIN915 87 4 08.933.0003 Cheese head screw M8x25 DIN912 88 7 08.642.0008 Hexagon nut M10 DIN934 89 4 08.643.0042 Countersunk screw M3x10 DIN966 90 4 08.643.0049 Countersunk screw M4x10 DIN966 91 5 08.643.0086 Countersunk screw M5x10 DIN966 93 1 08.521.0008 Fitting key 4x4x8 DIN6885 94 E2/E3 5 08.703.0001 Woodruff key 5x6,5 DIN6888 95 2 08.933.0059 Cheese head screw M4x10 DIN6912 96 3 08.933.0137 Cheese head screw M8x16 DIN6912 97 1 08.643.0076 Countersunk screw M5x16 DIN7991 98 6 08.643.0026 Countersunk screw M4x12 DIN7991 99 7 08.643.0037 Countersunk screw M5x12 DIN7991 100 2 08.643.0001 Countersunk screw M6x12 DIN7991 101 2 08.643.0021 Countersunk screw M6x25 DIN7991 102 2 08.181.0014 Spring washer A12 DIN127 103 2 08.933.0140 Cheese head screw M12x50 DIN912 104 E2/E3 1 08.933.0017 Cheese head screw M10x130 DIN912 105 4 08.643.0089 Countersunk screw M3x16 DIN7991 106 4 08.642.0004 Hexagon nut M3 DIN7985


Parts list, Section 3 Item Code Qty. Article no. Designation 401 E 1 05.441.0264 Motor 1.5KW 3x400-440V-50Hz 750min-1 402 E 1 05.441.0259 Motor 1.5KW 3x290/500V-50Hz 750min-1 403 E 1 05.441.0260 Motor 1.5KW 3x220/380V-50Hz 750min-1 404 E 1 05.441.0261 Motor 1.5KW 3x220/380V-60Hz 835min-1 405 E 1 05.441.0262 Motor 1.5KW 3x200/345V-50Hz 750min-1 406 E 1 05.441.0263 Motor 1.5KW 3x200/345V-60Hz 835min-1 407 E 1 05.441.0241 Motor 1.5KW 1x240V-50Hz 1430min-1 408 E 1 05.441.0242 Motor 1.5KW 1x220V-50Hz 1430min-1 409 E 1 05.441.0243 Motor 1.5KW 1x220V-60Hz 1690min-1 410 E 1 05.441.0244 Motor 1.5KW 1x200V-50Hz 1430min-1 411 E 1 05.441.0245 Motor 1.5KW 1x200V-60Hz 1690min-1 412 E 1 05.441.0246 Motor 1.5KW 1x127V-60Hz 1690min-1 414 E 1 05.441.0251 Motor 1.5KW 3x400-440V-50Hz 1430min-1 415 E 1 05.441.0252 Motor 1.5KW 3x290/500V-50Hz 1430min-1 416 E 1 05.441.0253 Motor 1.5KW 3x220/380V-50Hz 1430min-1 417 E 1 05.441.0254 Motor 1.5KW 3x220/380V-60Hz 1690min-1 418 E 1 05.441.0255 Motor 1.5KW 3x200/345V-50Hz 1430min-1 419 E 1 05.441.0256 Motor 1.5KW 3x200/345V-60Hz 1690min-1 421 E 4 03.720.0001 Cutter bar in stainless steel 426 E 18 05.908.0001 Indexable inser 431 E 1 05.748.0076 Controller with operator control for

220-440V 432 E 1 05.748.0079 Controller with operator control for

200V 435 E2 1 03.901.0041 Shaft for rotor disks for 750-835min-1 436 E3 1 03.901.0042 Shaft for rotor disks for 1430-1690min-1 450 1 05.731.0037 Type plate

Legend to Code : E ⇒ Spare part E1 ⇒ Spare parts with the same number may only be replaced together

Spare part assemblies

E1 = Art. no. 22.363.0001 Conical sleeve with grooved ball bearing

E2 = Art. no. 22.608.0005 Rotor with rotor disks and indexable inserts for 750-835min-1

E2 = Art. no. 22.608.0006 Spare part assembly: rotor with rotor disks and indexable inserts for 1430-1690min-1


List of spare parts for 2 years’ operation ( 8 hour single shift service / 30% duty cycle ^ 1320 operating hours )

Item Qty. Article no. Designation 12 1 03.111.0002 Seal for connector or item 5 14 1 05.114.0040 O-ring for 5 litre collecting tank 18 1 03.182.0024 Felt washer for motor shaft 24 2 03.241.0055 Rubber seal for housing top-bottom 25 1 03.241.0061 Rubber seal for door 421 4 03.720.0001 Cutter bar in stainless steel 426 18 05.908.0001 Indexable insert

Recommended stock of spare parts Item Qty. Article no. Designation

12 1 03.111.0002 Seal for connector or item 5 14 1 05.114.0040 O-ring for 5 litre collecting tank 18 1 03.182.0024 Felt washer for motor shaft 24 2 03.241.0055 Rubber seal for housing top-bottom 25 1 03.241.0061 Rubber seal for door 421 4 03.720.0001 Cutter bar in stainless steel 426 18 05.908.0001 Indexable insert 431 1 05.748.0076 Controller with operator control for

220-440 432 1 05.748.0079 Controller with operator control for

200V


Dimensional chart for SM2000 with standard hopper

I


Drawings, Part 1


Drawings, Part 2


Drawings, Part 3


Drawings, Part 4

Only dismantle the operator control and the controller at the screws and nuts marked A and B.

When undertaking repairs remove only the hex nuts and cap screws indicated with the letter A or B.


Parts lists and drawings for the accessories

Standard hopper Art.No. 01.747.0040

Item Qty. Article no. Designation 1 2 05.070.0008 Knob 2 1 05.042.0194 Pin 3 1 05.108.0029 Pressure piece 4 1 05.225.0016 Gripf 5 1 02.381.0002 Flap with chute 6 1 03.398.0004 Top plate 7 1 03.361.0044 Clamping pin 8 1 03.725.0018 Wooden slide 9 1 02.725.0019 Metal slide 10 1 03.731.0330 Label 11 1 02.747.0040 Connector 12 2 08.933.0006 Cheese head screw M4x8 DIN 84 13 2 08.701.0006 Washer A4.3 DIN 125 14 2 08.643.0001 Countersunk screw M6x12 DIN 7991 15 2 08.643.0039 Countersunk screw M6x45 DIN 7991 16 1 08.643.0048 Countersunk screw M8x16 DIN 7991 17 1 08.701.0001 Washer A8.4 DIN 125


Filter unit

Art.No. 22.187.0001 Item Qty. Article no. Designation

1 1 05.114.0040 O-ring 2 1 03.186.0025 Filter frame 3 1 03.604.0072 Ring, lower 4 1 03.604.0073 Ring, upper 5 2 05.867.0026 Catch 6 2 05.867.0027 Catch hook 7 8 08.933.0011 Countersunk screw M3x6 DIN 963-A2


Accessory box


1 1 03.222.0276 Casing in painted steel 2 2 08.933.0011 Flat head screw M5x10 DIN 84-A2

Long material hopper


1 1 03.111.0181 Seal in Vulkollan 2 1 02.725.0021 Slide in beech 3 1 03.785.0134 Hopper in stainless steel with support plate and cheese

head screws M6x12 DIN85-A2


Cutter roller with slide


1 1 02.608.0033 Rotor disks 1-6 with indexable inserts 1.1 18 03.361.0045 Clamping block 1.2 1 03.608.0033 Rotor disk no.1 1.3 5 03.608.0034 Rotor disks nos..2-6 1.4 1 03.901.0040 Shaft 1.5 18 05.908.0001 Indexable insert 1.6 18 08.933.0056 Cheese head screw M4x12 DIN912-8.8vz 1.7 4 08.933.0144 Cheese head screw M6x10 DIN6912-8.8vz 1.8 5 08.703.0001 Woodruff key 5x6,5 DIN6888

2 1 02.725.0020 Slide for cutter roller

2.1 1 05.225.0016 Grip 2.2 1 03.361.0044 Clamping pin 2.3 1 03.398.0004 Top plate 2.4 1 03.725.0020 Slide with rail and plate 2.5 2 08.643.0001 Countersunk screw M6x12 DIN7991-A2 2.6 2 08.643.0039 Countersunk screw M6x45 DIN7991-A2

3 1 08.933.0065 Cheese head screw M6x20 DIN912-8.8vz

(extractor screw)


Circuit diagrams

Circuit diagram for 1x220/230V

START

STOP

SM 2000

Legend :

A1 = Main switch

A2 = Controller

A3 = Door switch

A4 = Motor

A5 = Central earth in electronics enclosure



Legend :

A1 = Main switch

A2 = Controller

A3 = Door switch

A4 = Motor



Circuit diagram for 3x440V

Legend :

A1 = Main switch

A2 = Controller

A3 = Door switch

A4 = Motor



Circuit diagram for 3x380/400V for machines with letter “A” following the serial number

START

STOP

SM 2000

Legend :

A1 = Main switch

A2 = Controller

A3 = Door switch right

A4 = Motor


A7 = Door switch left


Circuit diagram for 1x220/230V AE=J for machines with letter “J” following the serial number

Legend :

A1 = Main switch

A2 = Controller


A4 = Motor





Legend :

A1 = Main switch

A2 = Controller


A4 = Motor




Circuit diagram for 3x440V AE=J for machines with letter “J” following the serial number

Legend :

A1 = Main switch

A2 = Controller


A4 = Motor




Modifications

1.) from 29.09.2006

The devices bear the revision mark "H" behind the serial number on the rating plate.

Safety Lock Part No. 05.656.0001 Glued with Loctite 243

2.) from 20.10.2006

The devices bear the revision mark "I" behind the serial number on the rating plate.

old = with revision mark "H" behind the serial number on the rating plate.

New = with revision mark "I" behind the serial number on the rating plate.

117 118 Pos. Stck. Art. Nr. Benennung Abmess. DIN Material 117 1 03.266.0225 Halteblech St1203 verzinkt 118 4 03.716.0005 Schwingmetalldämpfer 20x15


3.) 2007

The devices bear the revision mark "J" behind the serial number on the rating plate.

New = with revision mark "J" behind the serial number on the rating plate.

Pos. Stck. Art. Nr. Benennung Abmess. DIN Material 10 2 05.106.0023 Cable gland PG11 119 1 03.112.0117 Reducer 1.4301 120 1 05.703.0214 Switch 121 1 03.042.0321 Pin for Door, left 1.4305K 122 4 08.701.0005 Washer A5,3 125 St-A2K 123 4 08.933.0159 Cheese head screw M5x45 912 8.8-A2K 124 1 05.112.0092 Reducer M20x1,5 – PG11 125 1m 05.707.0060 Protective cable sleeve NW12


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