Operating Instructions for ZM50D1210 Bead Mill

Operating Instructions
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DEGOLD ZM50D1210 BEAD MILL

Chongqing Degold Machine Co., Ltd.

Shiyuan Industrial Park，Zhongliang Town，Shapingba District, Chongqing, China.
Tel: +86-574-88342320 Fax: +86-574-88342955 E-mail: [email protected]
Tel: +86-23-65540087 Fax: +86-23-65542126 E-mail: [email protected]

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 Operating Instructions for ZM50D1210 Bead Mill

Operating Instructions Hand-Over Declaration

（1） Machine: DEGOLD ZM50D1210 Bead Mill

（2） Machine No.: 210601

（3） Order No.: DG21061802

（4） Year of manufacture: 2021

（5） End buyer: SEMAPRO SRL

（6） Buyers’ Tel: 57-314-3159791

（7） Buyers’ Fax:

（8） Customer’s address:

（9） Languages: English Quality: 1

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 Operating Instructions for ZM50D1210 Bead Mill

Contents

1 Machine Data ................................................................................................................................................. 5

2 Specifications ............................................................................................................................................... 6
2.1 Bead Mill Drive................................................................................................................................... 6
2.2 Bead Mill Pump ................................................................................................................................. 6
2.3 Grinding Container ........................................................................................................................... 6
2.4 Signal Elements ................................................................................................................................ 6
2.5 Mill Equipment ................................................................................................................................... 6
2.6 Machine Limit Values....................................................................................................................... 6
2.7 Noise Emission Data ........................................................................................................................ 7
2.8 Dimension and Weight .................................................................................................................... 7
2.9 Working Environment ...................................................................................................................... 7
3 Application Field and Correct Operation ............................................................................................... 8
3.1 Dangers.................................................................................................................................................. 8
4 Safeties ........................................................................................................................................................... 9
4.1 Explanation of Symbols and Warnings....................................................................................... 9
4.1.1 Symbol: Warning Danger .................................................................................................... 9
4.1.2 Warning Notice....................................................................................................................... 9
4.1.3 Note ........................................................................................................................................... 9
4.2 General Safety ................................................................................................................................... 9
4.3 Operating Safety ............................................................................................................................... 9
4.4 Safety during Maintenance .......................................................................................................... 10
4.5 Suggestions for In-House Operating Guidelines ................................................................... 10
5. Description ................................................................................................................................................. 12
5.1 Construction Details ...................................................................................................................... 12
6. Requirements at Site of Installation ..................................................................................................... 16
6.1 Connections to be Supplied by Customer ............................................................................... 16
6.1.1 Feeding Vats ......................................................................................................................... 16
6.1.2 Electricity Supply ................................................................................................................ 16
6.1.3 Cooling Water Supply ........................................................................................................ 16
7. Transport and Installation ...................................................................................................................... 17
7.1 Transport Mill by Crane................................................................................................................. 17
7.2 Transport Mill by Fork Lift ............................................................................................................ 17
8. Description of Components, Controls................................................................................................. 18
9. Steps to Take before Start-up ................................................................................................................ 19
9.1 Installation and Alignment of the Machine .............................................................................. 19
9.2 Connection to the Electricity Supply ......................................................................................... 19
9.3 Filling in the Grinding Beads ....................................................................................................... 21
10. Start-Up ..................................................................................................................................................... 22
10.1 Starting Process ........................................................................................................................... 22
10.2 Interruption of Production.......................................................................................................... 22
10.3 Starting Mill After Using the EMERGENCY STOP Push Button ....................................... 22
10.4 Change of Product, Cleaning .................................................................................................... 23
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 Operating Instructions for ZM50D1210 Bead Mill
10.4.1 When Dealing With Compatible Products .................................................................. 23
10.4.2 When Dealing With Incompatible Products................................................................ 23
10.5 Emptying of the Grinding Chamber ......................................................................................... 23
10.6 Shutting Down the Mill ................................................................................................................ 24
11. Maintenance ............................................................................................................................................. 25
11.1 Care and Maintenance Instructions ......................................................................................... 25
11.1.1 Waste Disposal .................................................................................................................. 25
11.1.2 Care ....................................................................................................................................... 25
11.1.3 Routine Maintenance........................................................................................................ 25
11.2 Changing the Agitator Discs and Bushes .............................................................................. 25
11.3 Exchange Mechanical Seal ........................................................................................................ 27
12. Warn Signs and Description ................................................................................................................ 30
12.1 Electric warning sign ................................................................................................................... 30
13. Main Parts ................................................................................................................................................. 30
14. Trouble Shooting .................................................................................................................................... 31
15. Spare Parts List ....................................................................................................................................... 33
16. Enclosure......................................................................................................................................... 33
16.1 ZM50D Assembly Parts Diagram of Host Machine ........................................................... 33
16.2 ZM50 Circuit Diagram ............................................................................................................... 33
17. Appendix ................................................................................................................................................... 34

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 Operating Instructions for ZM50D1210 Bead Mill

1 Machine Data
Customer’s Name:

Customer’s Address:

Machine Name: DEGOLD BEAD MILL

Machine Type: ZM50D1210
Machine No.:
Date of Manufacture:

Manufacture’s Address: Shiyuan Industry

Zhongliang Town
Shapingba District
Chongqing
China.
Tel.: +86-23-65540087
Fax: +86-23-65542126
E-mail: [email protected]

Customer Service Chongqing Degold Machine Co., Ltd.

Ningbo Office
20th Floor, Yinzhou Commerce Building, No. 257
East Huifeng Road, Yinzhou District, Ningbo city,
Zhejiang, China.
Tel.: +86-574-88342320
Fax: +86-574-88342955
E-mail: [email protected]

Country of Origin: China

When ordering spare parts please quote:

Machine Type
Machine No.
Drawing No.
Description + Item No.
Required quantity

Note
Only original DEGOLD parts must be used. DEGOLD does not accept any liability
for damage resulting from the use of none DEGOLD spare parts, wear parts or
accessories.
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 Operating Instructions for ZM50D1210 Bead Mill

2 Specifications
2.1 Bead Mill Drive
Motor
Operating voltage V, Hz 380V, 3ph, 50Hz.
Nominal capacity KW 30
Type/Manufacturer Ex motor Made in China
Main motor model YB3200L-4

2.2 Bead Mill Pump

Pump
Type Double-diaphragm fluid transfer pump

2.3 Grinding Container

Net Volume liters 50
about 75%-80% of the cylinder
Grinding Medium Load liters
volume

2.4 Signal Elements

Max. 0-4 MPa at the mill inlet
Pressures gauge 1
with inductive contact
Max. 0-100℃ at the mill outlet,
Temperature gauge 1
with inductive contact
Contains the circuit breakers of
Control cabinet 1
the control

2.5 Mill Equipment

Grinding disc 13 Hard steel (GCr15)
Spacer 13 Hard steel (GCr15)
Locking cap 1 Hard steel (GCr15)
Inner cylinder 1 SS304
Front cover 1 Hard steel (GCr15)
O-ring 1 set Fluorous rubber

2.6 Machine Limit Values

Max. product pressure MPa 0.25
Max. product temperature ℃ 85
Temperature of cooling
℃ -15 to+80
water(min/max)
Max. pressure cylinder cooling MPa 0.6
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 Operating Instructions for ZM50D1210 Bead Mill
Original granularity of materials Μm ≤100

2.7 Noise Emission Data

When running under load, the noise of the ZM50D1210 bead mill shall be under 82dB(A).

2.8 Dimension and Weight

Length 2100mm
Width 1150mm
Height 1650mm
Net weight 1300kg

2.9 Working Environment

Temperature range for normal
10℃~45℃
use of the bead mill
Relative air humidity range for
≤95％ (when temperature+25℃)
normal use of the bead mill
Atmospheric pressure for
86~106kPa
normal use of bead mill

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 Operating Instructions for ZM50D1210 Bead Mill

3 Application Field and Correct Operation

The DEGOLD Bead Mill may only be used for the application specified.
The bead mill is only suitable for continuous dispersion and wet
grinding for solids suspended in a liquid phase.

Operating regulations
a. No products or materials may be processed which might, under the influence of pressure,
temperature, and shear, produce uncontrolled reactions exceeding the machine limits. Such
uncontrolled reactions are: a rise in viscosity or temperature, spontaneous increase in hardness,
foaming, or gas secretion.
b. Please note that even within the machine limits the milling process might change some product
characteristics in an unacceptable way or even destroy them.
c. Before operating the machine ensure that the product will not react to the milling process in an
undesirable or even totally uncontrollable way.
d. The material to be milled must be pumped and its viscosity must not increase in the
dispersion/milling process in such a way that the product pump can no longer discharge the
milled material.

Proper use includes compliance with the manufacture’s instructions regarding

commissioning, operation, and servicing as well as prevention of accidents due to incorrect
handling. The machine may only be operated and maintained by qualified employees who are
familiar with the machine and have been informed about potential dangers.

Any other uses will be considered improper. The manufacturer does not accept liability for
any damages resulting from improper use.

The operating instructions constitute part of the machine delivery package and, in the case of
resale, must be passed on to the new owner.

3.1 Dangers

In spite of all precautions, some danger may remain. Residual dangers are
potential, not very obvious hazards, for example:

a. Injury during set-up, especially by worn, sharp- edged agitator discs

b. Fire risk from leakages
c. Risks caused by the product, such as allergies, skin irritations, or burns
- Risks due to malfunctions of the control system
- Risks involved in operating electrical controls

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 Operating Instructions for ZM50D1210 Bead Mill

4 Safeties
4.1 Explanation of Symbols and Warnings
4.1.1 Symbol: Warning Danger

You will see this symbol next to all safety notices concerning danger to life
and limb. Follow these instructions and work carefully. At the same time
observe all valid laws and safety and accident prevention regulations.

4.1.2 Warning Notice

“WARNING” marks places where special care should be taken that instructions and
accurate procedures are followed and damage to the machine avoided.

4.1.3 Note

“Note” indicates application advice or correct working procedures.

4.2 General Safety

The ZM DEGOLD Bead Mill, hereafter called “the mill”, is constructed according to the most modern
technical standards and operationally reliable. Working procedures are, however, such, that certain
places and parts of the mill cannot be made totally safe without impairing its operation. Therefore, it is
of great importance that good personal safety practices be employed to safeguard personnel and mill.
This mill can be dangerous if used improperly by untrained personnel or employed for other
uses than the one specified.

a. Read and carefully observe the mill operating instructions as well as all safety notices
before unpacking, installing, and starting up the machine.
b. Store the operating instructions in an easily accessible place close to the mill.
c. The mill may only be set up, operated and maintained by authorized, qualified employees,
familiar with the machine.
d. All local safety and accident prevention regulations apply for the operation of the machine;
these should be noted and followed.
e. Observe attached notices and warning signs.
f. Always wear closed-fitting clothes while working the machine.
g. Tie away and cover long hair. Do not wear jewelry such as necklaces and rings. Thy might
get caught in the machine and cause injury.
h. Immediately see a doctor in case of injuries, accidents, or skin irritations.

4.3 Operating Safety

a. Before undertaking any mill maintenance work, the EMERGENCY STOP push button must be
pressed!
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 Operating Instructions for ZM50D1210 Bead Mill
b. Switch off main supply.
c. It is only possible to restart the mill after the EMERGENCY STOP push button has been released.
d. In situations which may threaten the safety of the operating personnel or the mill, the mill can be
stopped by pressing the EMERGENCY STOP push button in the control panel.
e. Before starting the mill check whether any tools or instruments have been left in the mill and
remove them.
f. If the mill has stopped for no apparent reason, do not switch it back on immediately. It may be that
someone stopped the mill to carry out some manual adjustments’ and forgot to secure it against
being restarted. An unexpected restart could lead to serious injuries to a colleague.
g. During operational interruptions the mill must be stopped and secured with the EMERGENCY
STOP push button pressed.
h. The milled product must not come into contact with mucous membranes or enter eyes, mouth or
nose. If this should happen, rinse immediately with tap water, or follow in-house first aid
measures.
i. Do not change, dismantle, circumvent or bridge any safety devices.
j. Immediately replace worn or damaged accelerators.

4.4 Safety during Maintenance

All maintenance and repair work must be carried out by authorized, qualified personnel. The special
risks of working on electrical equipment have to be taken into account.
a. Only allow experienced, qualified personnel to set up the mill, and only allow authorized
electricians to carry out any electrical work.
b. Before working on pumps and pressured connections (tubes, pipes), depressurize them to
prevent the risk of injury.
c. Turn off the main supply.
d. Immediately replace any notices, warning signs, or safety labels that have become damaged or
been removed from the mill.
e. Remount all safety devices that have been removed during maintenance work.
f. Unauthorized alterations and modifications of the mill impair the safety of its operators and of the
mill itself and should not be undertaken.
g. Spare parts must conform to the technical requirements of the machine manufacturer.
h. Before opening, rinse the machine with an appropriate rinsing medium.
i. Ensure that the mill has cooled down before opening.
j. Do not touch the cylinder with hands.

4.5 Suggestions for In-House Operating Guidelines

Operating guidelines are instructions given out by an employer to ensure safe operating processed.
They are mandatory instructions imposed by the employer under his authority to issue directives. The
employees are bound by the accident prevention regulations to observe these instructions.

Employees must agree to and/or be instructed concerning the following:

a. The operator must agree only to run the machine in impeccable condition.
b. The risks involved in the handling of the materials, and the necessary safety measures and rules
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 Operating Instructions for ZM50D1210 Bead Mill
of conduct, including instructions for emergencies and First Aid.
c. Permitted operational data (e.g. settings for the safety and monitoring devices).
d. Maintenance.
e. Safe handling of the product.
f. Environmental protection regulations.
g. The operating company is responsible for ensuring, by way of instructions and supervision, a
clean and orderly working environment for the machine.
h. The operating company must establish unequivocal rules concerning the responsibilities for
operation and maintenance of the mill, to be observed by all parties involved, so that, from a
safety point of view, all responsibilities are clearly defined.
i. The mill operator is obliged to inform his superior immediately of any changes to the machine that
could impair its safety.
j. Observe attached notices and warning signs.

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 Operating Instructions for ZM50D1210 Bead Mill

5. Description
DEGOLD ZM bead mill is a high efficiency grinding and dispersion equipment which is widely used in
industrial departments concerning coating, coloring agent, printing ink, drug, magnetic recording
materials, ferrite, light-sensitive film, strontium carbonate, etc.

The necessary energy for dispersion and grinding is transmitted to the grinding beads via easily
exchangeable agitator discs mounted on an agitator shaft. The material to be milled is constantly fed
into the mill by a separate product pump.

Special Advantages

a. Grinding container with optimal length/diameter ratio.

b. The special shape of the agitator discs guarantees the most energy-efficient use and prevents
compaction of the grinding beads.

c. Forced cooling water flow for high cooling efficiency.

d. Shape and number of agitator discs can easily be adapted to the product to be processed.

e. Wear parts that come into contact with the product are easily exchangeable and are available,
also for retro-fitting, in various hard-wearing materials.

5.1 Construction Details

Grinding Container
The net volume of grinding container is 50L. The inner cylinder is surrounded by spiral cooling device
to ensure low temperature.
The whole grinding container can be pulled out completely and swiveled after the screws on the
stator flange have been loosened.
It is changeable design, you can only replace the inner grinding cylinder when it is abrasive.

Drive
Motor output, connection data and enclosure as required and ordered. Speed transmission to the
agitator shaft by poly-v-belts. Different speeds are achieved by fitting the appropriate motor pulleys.

Control Devices
ON/OFF- buttons with indicator lamps for the control of the motor contactors mounted in a control
panel.

Grinding Discs

They are easily exchangeable, mounted on agitator shaft with spacers. The agitator shaft speed is
about 1120r/min. We assemble “Type A” grinding discs in ZM50D1210.

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 Operating Instructions for ZM50D1210 Bead Mill

Four types of dispersion discs

Back Cover

The product feed, pressure gauge are mounted on the end cover

Shaft Seal

Sealing of the grinding cylinder on the bearing side is achieved by a double mechanical seal. The
seal is cooled by oil circle system set in the bottom of the machine.

Grinding Beads Separation

The separation of the grinding beads is achieved by a dynamic gap separator, consisting of a stator in
the front cover and a rotor on the agitator shaft.

Mechanical Seal

The mill adopts single mechanical seal and instruction is shown as following picture:

Single mechanical seal of the mill

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 Operating Instructions for ZM50D1210 Bead Mill

Lubrication Devices

The lubrication devices including:

a. The oil tank assembled in the mill house where beside the motor location;

b. The oil mirror located on the top of the mill body, users can observe the oil condition by it.

The lubrication oil is pumped into the mechanical seal device and circulated through a gear pump to
guarantee the low temperature of the seal and the flow ≥60L/h.

Operator could use several oils such as transformer oil, N5 precision machine tool oil or high speed
machine oil as the lubrication oil.

Notes:
a. Oil level can be observed from the oil mirror; if accumulated oil loss is no more than
2mL/h, it is normal; but if the accumulated oil loss is more than 2mL/h, it should polish the
seal ring (pay attention to remove the leakage from oil seal)
b. Operators can judge whether the mechanical seal is in good condition or not by oil color
changes.
c. Lubrication liquid shall be regularly replenished avoid friction; if the lubrication liquid is
not circulated, the machine shall be stopped for overhauling, and the lubrication liquid shall
be replaced after each overhauling.

Grinding Beads

Filling ratio is 75%-85% of the container volume. The choice of grinding beads depends on product to
be processed.

Feeding Pump

Diaphragm pump
Please refer to the enclosed diaphragm pump operation instruction.

Pressure Gauge as well as Temperature Gauge

Please refer to the Chapter 8 to check their positions.

Pressure gauge is used for adjusting the pressure to a proper position （~0.1MPa）according to
production requirements.
Temperature gauge is used for observing the discharging temperature.
Pressure gauge adopts transmission hydraulic type: one side of the capsule and pressure gauge
inside are full of oil. When a membrane moves, the oil is pressed to deform the pressure gauge spring
so as to indicate the pressure. According to hydraulic transmission principle that the pressures at the
two ends of the membrane are equal; therefore, the pressure reflected on the pressure gauge is also
the pressure in the grinding container.
The oil filling method is shown in following figure.

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 Operating Instructions for ZM50D1210 Bead Mill

Figure of operation methods for injecting oil into the mill capsule and the pressure gauge.

Operation steps:
a. Tighten flange bolts of the capsules after cleaning capsules, membranes, and washers. Seal
washers are made of red copper or ploy teflon in order to guarantee that they are not leakage.
And please replace damaged seal washers immediately. There is a M6 nut in the center of the
membrane, and the membrane shall be pulled by special tools such as nut, studs and carrying
poles.
b. Inject machine oil into capsule. Screw the M6 nut manually in order to pull membrane out, about
2-3mm after it is filled. Please don't pull it out too much, otherwise, capsules will be distorted
forever. And then the oil level will drop, please loose the nut to reset the membrane, and air
bubble will escape from capsule which indicate oil level can not be reset, then fill in oil again.
Please repeat the action for several times until there is no air bubble escaping from the capsule,
which indicate that the air in the capsule has be discharged out completely. Finally, pull the
membrane out to 2-3mm, filling the capsule and laying the capsule flatly.
c. Convert the pressure gauge and inject oil into the spring tube by an oil gun. Blow air into the
spring tube by mouth after the spring tube is fully injected for the first time because the spring
tube is full of air.Inject oil again after the oil level drops and repeat the same action for several
times until the oil level does not drop, which means that the air is discharged out.
d. Tighten the pressure gauge and the capsule, take down the M6 nut and the carrying pole, then oil
injection is finished. Ordinary speaking, inner air will be totally discharged by this way. The
pressure gauge value is slightly departs from "0" because of membrane resilience force. Please
sensitively swing membrane by hand, and you can see the pointer is going to stretch. Pressure
gauge error normally will not exceed 0.1-0.3kg/cm² so it won't influence bead mill operation.

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 Operating Instructions for ZM50D1210 Bead Mill

6. Requirements at Site of Installation

Flour:
Horizontal industry floor with a maximum allowed surface load of at least 200kp/cm2.

Space requirement for operation and maintenance:

Enough clear space around the mill to have access to anything at any time.

6.1 Connections to be Supplied by Customer

6.1.1 Feeding Vats
Feeding vats with a discharging valve shall be provided to be convenient for operation. The height of
the collecting vat shall be equal to or lower than the height of container discharge so as to be benefit
for discharging and cleaning.

6.1.2 Electricity Supply

Building safety conform to regulations.
The electrical system comprises main circuit, control circuit as well as lighting indicator, and auxiliary
circuit, etc.
If one of the main motor or the pump is turned off because of overloading, it will automatically stop; If
the pump is not started, the main motor can not be started as well, but can be jogged.
The ZM30 Electrical Principle Figure of the bead mill is enclosed in Chapter17.1

6.1.3 Cooling Water Supply

The water consumption volume is increased or reduced according to the water temperature, product
rigidity, required grinding fineness, material viscosity, loading volume of the grinding medium as well
as the speed of the agitator disc. The cooling water shall maintain a pressure of 0.1~0.2MPa. If the
grinded material is particularly sensitive to the temperature, please select chill water or add a cooling
device in the the end of water inlet

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 Operating Instructions for ZM50D1210 Bead Mill

7. Transport and Installation

Transport must be done by experienced carries. Transport should, if at all
possible, be done by crane, as shown in following figure.

The machine is delivered fastened to the base of a crate and wrapped in a plastic sheet or packed in
a wooden crate and fastened to the base of the crate. Before transporting, make sure the out
important parts are removed.

7.1 Transport Mill by Crane

WARNING
e. The mill must not be lifted by the grinding container or the agitator shaft!
f. Fasten lifting gears to the machine. When using a standard motor fasten the lifting gears
as shown in below figure to the machine housing and on the tabs of the motor.
g. Tighten lifting gears carefully and secure them against displacement.
h. Ensure that all lifting gears are suspended freely and do not damage anything.
i. Lift the machine slowly and carefully and transport it to the site of installation.
j. The machine must hang horizontally from the crane. If necessary, the lighter side of the
machine may have to be weighted. Avoid shocks and bumps.

7.2 Transport Mill by Fork Lift

Only transport the mill with a suitable fork lift if no crane is available.
Transport y fork lift is dangerous. There is a risk of tilting, as the center of
gravity is not at the middle of the mill. So lift mill from the floor and
transport carefully to the point of installation.
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 Operating Instructions for ZM50D1210 Bead Mill

8. Description of Components, Controls

1 Pressure Gauge (not Ex) 6 Air valve

2 Grinding container 7 Temperature gauge (not Ex)
3 Grinding discs 8 Control panel (not Ex)
4 Mill house 9 Main motor (not Ex)
5 Pump 10 Electric cabinet (not Ex)

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 Operating Instructions for ZM50D1210 Bead Mill

9. Steps to Take before Start-up

Only qualified personnel who are familiar with the operating instructions are permitted to operate the
mill. They must have sufficient experience in process engineering and be informed about accident
prevention regulations in explosion protected areas.
Check before each start-up.

WARNING
Before the initial machine start-up the customer must take the following measures:
a. Installation and alignment of the machine (chapter 9.1).
b. Connection to the electricity supply.
c. Installation of the cooling water connection.
d. Installation of the product feed hose.
e. Filling with oil into the tank in the mill body.
f. Filling the grinding beads into the mill.

Note:
During grinding operation, fix the conveying value of the pump at a certain value at first and
adjust the flow according to the needed production fineness after checking the fineness of the
grinded products. The adjustment of the conveying ability of the pump and the arrangement
for the grinding and dispersion circling frequency are a process for technology optimization,
and shall be preferably selected according to the actual condition.

9.1 Installation and Alignment of the Machine

A level, shock and vibration free floor with a permissible surface pressure which at least 200 kp/cm2
is required for the installation of the machine.
You should link the following parts according to the ranks:
Feeding material container with bottom outflow → product pump → DEGOLD bead mill → Container
for milled product

9.2 Connection to the Electricity Supply

WARNING
The initial start up of the machine must be carried out by qualified personnel according to the
circuit diagram.
a. Before and during the whole installation procedure the machine must be secured against
unauthorized operation. Press the EMERGENCY STOP push button and switch off main supply.
b. Switch off main supply.

Note:
a. The wiring of all devices has already been carried out by the manufacturer, according to the
circuit diagram.
b. Ensure that the local operating voltage, frequency, and fuse protection correspond to the data on
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 Operating Instructions for ZM50D1210 Bead Mill
the type plate and the specifications. In case of discrepancies the machine should not be
connected to the main supply.
c. Feed the power supply through the cable entry in the control cabinet and, according to the circuit
diagram, connect it to the terminals, zero and ground. After this, install all connecting cables
between control cabinet and mill, according to the circuit diagram. When doing this the local
standards must be observed.
d. Checking the direction of rotation. Generally, we check the motor rotation before selling.

The following controls and indicators are mounted in the control panel:

Mill rotary speed

Speed regulation
Annunciator
Pump Start
Mill Start
Pilot Lamp
Pump Stop
Mill Stop
Emergency Stop

WARNING
The mechanical seal must never run dry. Always detach the poly-v-belt before checking the
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 Operating Instructions for ZM50D1210 Bead Mill
direction of rotation. You can see the situation from the oil mirror and motor parts beside the
mill.

9.3 Filling in the Grinding Beads

WARNING
Only carry out this procedure with a depressured grinding container and the connecting
rubes closed off. Do not allow the ill to run dry.
When filling the grinding mediums, firstly dismount the union below the pressure switch capsule; and
fill the bead mediums prepared and weighted in through the hole. At this time, the majority of the
medium will flow into the cylinder; the excess material can be led-in by slightly starting the main motor.
Since the medium at this time is dry, the rotating speed can not be led to reach the full speed, to
prevent the cracking of the medium. Watch out that the volume for medium filling should be about
75%-85% of the cylinder volume; if excess, the load is overloading; and if insufficient, the efficiency
can not be exerted.

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 Operating Instructions for ZM50D1210 Bead Mill

10. Start-Up
Only qualified personnel who are familiar with the operating instructions and have been given
the necessary training by a technician from the manufacturer are permitted to operate the mill.
They must have sufficient experience in process engineering and be informed about accident
prevention regulations in explosion protected areas.
Check the machine before each start-up.

10.1 Starting Process

a. Open cooling or chilling water inlet.
b. Press product pump ON push button and set a low throughput rate.
c. As soon as the pressure increases in the grinding container, switch on the main motor for the
agitator shaft with the ON push button.
d. Check the quality of the milled product and, if necessary, decrease or increase the product feed
rate with the product pump variator.

WARNING
When working with highly viscous products, the grinding beads have to be initially wetted by
first filling in the liquid phase of the product to be milled.

Note:
The flow rate of the product to be milled depends on the required final fineness.
Higher pressure gauge value indicates that the milling conditions are not optimal. The pressure can
be reduced by slowing down the flow rate or reducing the viscosity of the product to be milled.
The speed of the agitator shaft influences the fineness and the milling temperature. The higher the
speed, the greater the fineness achieved. High speeds increase the milling temperature and the wear
of mill components and grinding beads.

10.2 Interruption of Production

The mill may be left filled with materials to be milled for short periods, e.g. over night. If there is,
however, any danger that the material to be milled might sediment in the pump or feeding tubes, the
system will have to be given a short rinse. The same is valid for products that tend to thicken
considerably when cooling down.

10.3 Starting Mill After Using the EMERGENCY STOP Push Button
a, if the mill has switched off for no apparent reason, do not immediately switch it back on. It may be
that someone has stopped the mill to carry out some manual adjustments and has forgotten to secure
it against being restarted. An unexpected restart could lead to serious injuries to a colleague.
b. Remedy cause of disruption.
d. Check that no one else is working on the mill.
d. Release EMERGENCY STOP push button.
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 Operating Instructions for ZM50D1210 Bead Mill

10.4 Change of Product, Cleaning

10.4.1 When Dealing With Compatible Products
Rinse the system at the end of the batch, while the agitator shaft is still running, with part of the liquid
phase of the product that has been kept back for this purpose.
Should this not clean the machine sufficiently, pump, with the agitator shaft running, a high
throughput of rinsing liquid in circulation through the system until the connecting tubes are also clean.
Pump the new product into the mill with a low pump setting and the agitator shaft stationary until the
pressure rises in the product inlet or until the new product emerges from the mill outlet. Switch on the
mill and set the required throughput.

10.4.2 When Dealing With Incompatible Products

Rinse the system at the end of the batch, while the agitator shaft is still running, with part of the liquid
phase of the product that has been kept back for this purpose.
Pump, with the agitator shaft running, a high throughput of rinsing liquid that is compatible with the
new product in circulation through the system until the connecting tubes are also clean.
Pump the new product into the mill with a low pump setting and the agitator shaft stationary, until the
pressure rises in the product inlet or until the new product emerges from the mill exit.

10.5 Emptying of the Grinding Chamber

WARNING
Rinsing liquids must be compatible with the mill seals! Grinding container must not be under
pressure!
a. With the agitator shaft running, rinse mill with a suitable liquid.
b. Switch off the mill and main supply.
c. Prepare a container behind the mill bead outlet plate to hold the beads.
d. Remove the screw and switch on the front cover, let the materials and beads flow down from the
mill.
e. Loosen screws in the seal flange, and then slide the grinding container; let the materials and
beads fall down to the below plate. It is necessary to rag the beads covered in the agitator shaft
and agitator discs by hand.

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 Operating Instructions for ZM50D1210 Bead Mill

f. Container opening position is showed in above picture.

WARNING
The grinding container is very heavy!
Be careful not to damage the agitator when you remove the grinding container.
a. Carefully pull back the grinding container away from the housing.
b. Clean the agitator and rinse the rest of the grinding media out of the grinding container.

10.6 Shutting Down the Mill

Should the mill be shut down for a longer period of time, for example during factory vacations,
the following measures have to be carried out first:
Rinsing liquids must be compatible with the mill seals!
a. With the agitator shaft running, rinse mill with a suitable liquid.
b. Drain the liquid.
c. Secure mill against switching-on by pressing the EMERGENCY STOP button.
d. Switch off the mill and main supply.
e. Empty the grinding chamber and dry all wear parts that come into contact with the product.
f. Refit the grinding container and screw it.

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 Operating Instructions for ZM50D1210 Bead Mill

11. Maintenance
11.1 Care and Maintenance Instructions
Service and maintenance measures should only be carried out by experienced
personnel observing the applicable safety regulations. Before and during all
maintenance operations, secure the mill against unauthorized operation. Press
EMERGENCY STOP push button. Switch off the main supply.

WARNING
Rinsing liquids must be selected in accordance with the chemical stability of the seals!

11.1.1 Waste Disposal

When selecting the rinsing liquids consider their environmental friendliness, health risks, and local
regulations for waste disposal.

11.1.2 Care
Clean the mill regularly.
If you cover the mill with plastic sheets to prevent if from getting dirty, keep the ventilation grids in the
doors clear. The main motor needs an unimpeded exchange of air.

11.1.3 Routine Maintenance

a. Regular checks and adds grinding beads.
b. When the machine is operating, the circling condition of the mechanical seal cooling liquid can be
checked through a viewing mirror and the pipeline, and corresponding measures can be adopted.
c. Check the circling condition of the cooling water.
When carrying out major overhauling on the machine, dismount all the discharging and drainage
water pipes, and find out whether the flow condition in the cylinder meets the requirement or not, and
exchange new machine oil for the mechanical seal cooling liquid.

11.2 Changing the Agitator Discs and Bushes

11.2.1 Agitator Shaft and Agitator Disc Types
Our mill agitator shaft and agitator disc are listed in the following pictures.
We assemble “Type A” in ZM50D1210.

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 Operating Instructions for ZM50D1210 Bead Mill

The figure of agitator shaft and discs rotation direction

11.2.2 Dismantling
Dismantling grinding container first according to chapter 10.5, and then doing following steps:
a. Loosen and remove the tension screw (in the end side of the agitator shaft), spacers (between
agitator discs), and pins (in the groove) from the agitator shaft.
b. Carefully remove agitator discs and store them in a safe place.

WARNING
Ensure that the agitator discs are installed with their pointed ends away from the rotating
direction of the agitator shaft.

11.2.3 Assembly
After cleaning, repairing or changing the discs, you should do as following to assemble the discs:
a. Clean the dispersion agitator and then assemble a bushing first, and then you should pay attention
to assemble a small pin in the bushing.
b. Slide every agitator discs with one spacers in between, onto the agitator shaft.
c. Stick on tension cap and screw it tight with the tension screw in the end of the agitator shaft.
d. Carefully insert the grinding container and fasten ti with 4 cup nuts and spring washer to the seal
flange.
e. Screw together front cover with 4 cap nuts and washers with grinding container.
f. Make sure that all the loosened connections are reattached properly.
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 Operating Instructions for ZM50D1210 Bead Mill
g. Filling in the cleaned grinding beads and complement if neccessary.
h. Start-up mill.

11.3 Exchange Mechanical Seal

Exchanging the single end plane 131 series mechanical seal shall be carried out according to
following steps according to drawing in Chapter17.3, Sketch Diagram of Installation of Mechanical
Seal.
a. Slide the grinding container away from the mill.
b. Dismount agitator discs components.
c. Clean the agitator shaft by solvent, and take down the seal flange.
d. Dismount the two plastic pipes (5) from quick connector, and remove the gap separator (3) away.
e. Take down the seal ring and it is strictly forbidden to strike gap separator when taking seal ring
down.
f. Dismount clamping ring (10) and transmission ring (11). Please clean rotor and stator after
dismounting all the parts.
g. Reassemble the mechanical seal.
h. Mount the transmission ring (11).
i. Mount the spring (12) into the small hole of the transmission ring (11), adhere the spring with a little
lubricating grease, and maintain them at the right position.
j. Mount the clamping ring (10) and the O-ring on the agitator shaft, and then mount the clamping ring
(10) and the O-seal ring into the rotor, make sure the clamping ring (10) is adhered with the small
spring. Check whether the O-ring is proper position or not, and whether the pin of the transmission
ring (11) passes the holes of the clamping ring (10) and the rotating ring (8) or not.
k. Install gap separator (3) correctly.
l. Then connect the plastic pipes.
m. Mount seal flange (1) on the machine base and check whether stator is totally located in the
middle or not. If not, adjust it.
n. Assemble the agitator discs onto the shaft.
o. Rotate the shaft by hand to maintain the correct gaps between stator and rotor.
p. Mount grinding container and check the position of the lubrication liquid.

The installation site of the main frame must not be altered for a long term, the foundation must
be solid and firm and the installation position shall take the technology route, electrical wiring,
water supply and drainage piping, operation and maintenance and ventilation condition for
consideration.

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Operating Instructions for ZM50D1210 Bead Mill

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 Operating Instructions for ZM50D1210 Bead Mill
11.4 Adjust Motor Belt
The motor is mounted on a flat with an adjustable height (see following figure for the adjustment of
the motor belt), through adjusting the height of the flat and tensioning the V-belt. Its degree of
tightness is ok when pressing down the middle part of the V-belt by hand for 8~15mm.

Figure Adjustment on the belt of the main motor

WARNING
You should pay attention to the orientation of the discs. You can see from the first picture
above. The direction of the discs rotation must be clockwise.

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 Operating Instructions for ZM50D1210 Bead Mill

12. Warn Signs and Description

Although our mill is good quality, there also existing some hazards, and to help users avoid dangers,
we attach some warning signs on the machine.

12.1 Electric warning sign

The electric cabinet is dangerous, so users should be stay away when you
want to start and repair the electric system.

13. Main Parts

The main parts of the mill are shown in enclosed Chapter17.2.

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 Operating Instructions for ZM50D1210 Bead Mill

14. Trouble Shooting

No. Fault Cause analysis Remedy Remarks

Whether the fuse is burnt out or not and

The fuse is burnt out
whether there is power source or not
The main The thermal relay is
Whether the thermal relay works or not
1 motor does not damaged
work.
The pressure controller is Check whether the switch of the
disconnected or wrong. pressure gauge works or not

Start the switch of the pump, and make

The switch of the pump is
sure that the switch is at the position of
not started.
“start”.
Check the air pipeline to make sure that
There is air leakage or no the connection is reliable, and there is
The pump
gas supply. no air leakage and the air supply is
does not work.
sufficient.
Check the working or normal situation
2 The solenoid valve does of the solenoid valve works to
not work. guarantee the solenoid work normally
and effectively.
Check whether the safety device
The pressure controller is
pressure controller works or not, and
damaged
find out the reasons thereof.
Check whether the inside of the pump
The inside of the pump is
is blocked or not, to guarantee there is
possibly locked.
no stagnation and blocking.
Even if the Adjust the moderate tightness of the
The V-belt is slipping.
main motor V-belt.
operates, the
3
dispersion The dispersion shaft is Check whether the dispersion shaft is
shaft does not blocked. blocked by medium or material or not.
rotate
The material viscosity is Adjust the moderate viscosity of the
too high. material.
The main The added volume of The quantity of the added mediums is
motor operates the medium is too not suitable to be too large, and shall
4
under large. be adjusted to a proper volume.
overloading. There is abnormal Immediately stop the machine, shut
condition on the electrical down the power source, and check the
circuit. circuit to guarantee the connection is
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 Operating Instructions for ZM50D1210 Bead Mill

No. Fault Cause analysis Remedy Remarks

correct and reliable.

The material viscosity is Adjust the moderate viscosity of the

too high. material.
The added volume of The quantity of the inputted medium is
the medium is too not suitable to be too large, and shall
The pressure
large. be adjusted to a proper volume.
of the feeding
5 The delivery of the
pump is too Adjust the height of the delivery of the
discharging pipe
high. pipeline from the cylinder discharging
pipeline is too high or
pipeline, or the length of the pipeline.
the pipeline is too long.
The discharging part is Clear and clean the discharging part to
blocked. guarantee cleaning and no blocking.
The medium added
volume is too small, or the Adjust the moderate medium density or
medium density is too added volume.
small.
The material
Mechanical temperature is too low Adjust the moderate temperature or
6
vibration or the viscosity is too viscosity of the material.
high.
The tightness of the Adjust the moderate tightness degree
V-belt is not proper. of the V-belt.
The dispersion shaft is
Exchange the dispersion shaft.
bent and deformed.
The safety There is abnormal Carefully check and adjust the safety
7 device does occurrence appearing instruments to reach the regulated
not work. on the safety device. requirements
Dirt enters the
The feeding
compressed air and
8 pump does not Overhaul the air filter.
affects the normal start
work normally.
of the pump.
When sucking the
medium which is easily Install a valve at the inlet of the pump;
frozen, the pump will when the pump is stopped, firstly shut
It is difficult to not be started up down the valve, and then start the
9
start the pump. immediately. It will pump for several minutes until the
cause blocking and medium in the pump is completely
clamping and difficult discharged out.
pump start.

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 Operating Instructions for ZM50D1210 Bead Mill

15. Spare Parts List

Specification
Location Name QTY Material Remarks
&code
1 V-belt SPB2200 5 Rubber GB1171-74
2 Bearing 6215 1 Component GB/T276

3 Bearing 6218 2 Component GB/T276

4 O-ring D150×5.7 1 Fluorous rubber GB1235-76

5 Temperature gauge WSSF-DX411 1 Component BLD

6 O-ring D300×5.7 2 Fluorous rubber GB1235-76

7 O-ring D210×5.7 1 Fluorous rubber GB1235-76
8 Front cover ZM50 132 1 Hard steel (410)
Inner grinding
9 ZM50 116 1 SS304
cylinder
10 Grinding disc ZM50 117 13 GCr15
11 Spacer ZM50 118 12 304
12 Pressure gauge YTXHP-100HL02 1 Component BLD
13 O-ring D45×3.1 2 Fluorous rubber GB1235-76
14 Back cover ZM50 122 1 Hard steel (410)
15 Rotor ZM50 128 1 Hard alloy (YG6)
16 Stator ZM50 129 1 Hard alloy (YG6)
17 O-ring d100×5.7 1 PTFE GB1235-76

18,19 Single mechanical seal 131/085 1 Component

20 Oil frame (D) TC140×110×14 1 Rubber

21 Fix ring (D) 131 853 1 45

22 O-ring (D) d85×5.7 1 PTFE GB1235-76

Round spiral
23 1.3×8.2×22 12 65Mn
compressed spring (D)
24 Driving ring (D) 131 854 1 45

16. Enclosure
16.1 ZM50D Assembly Parts Diagram of Host Machine

16.2 ZM50 Circuit Diagram

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 Operating Instructions for ZM50D1210 Bead Mill

17. Appendix

Certificate of new equipment and Warranty

Name Horizontal Bead Mill Model No. ZM50D1210

Q/DG1101-2014
Performing Standard
Q/DG1101-2014 Horizontal closed bead mill
Produce Date 2021 Produce No. 210601

Warranty：
1. Hereby certify this equipment has passed our company's strict quality management
system, qualified, excellent features, in line with our enterprise standard.
2. We will provide maintenance to the equipment for free during the 1st year since the
date of leaving factory, in case of malfunction happens under correct and normal
operation.
3. If the user can not get the leaving date certificate of this equipment, then can calculate
the warranty period according to produce date on the name plate of equipment.
4. In case of user change or refit the equipment characters or functions without
notification from supplier, any malfunction happens during warranty period, user shall
handle the own risk.
5. The company responsible for this product, no more than the original price.
6. This certificate is invalid without inspection seal of our company.

QC:

QC department:

Date:
Chongqing Degold Machine Co., Ltd.
Shiyuan Industrial Park，Zhongliang Town，Shapingba District, Chongqing, China.
Tel: +86-574-88342320 Fax: +86-574-88342955 E-mail: [email protected]
Tel: +86-23-65540087 Fax: +86-23-65542126 E-mail: [email protected]

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技术参数TECHNICAL DATA