ND4L Planetary Ball Mill Manual
Contents
1. 7 Explanation of function code 1 01 Cd05 Cd06 Cd07 Cd08 Cd09 and Cd13 are fixed default values and shall not be changed or the accuracy of such parameters will be affected 2 Settings Cd07 and Cd08 are to keep a time interval between rotations in reverse directions in the automatic direction reversal operation mode Settings that are too small will possibly affect the life of motor 3 When Cd10 is set at 0 LED display shows the frequency after the VFD starts up When it is set at 1 LED display shows the rotating speed 4 When 11 reads 0 LED display shows default rotation direction ball mill operates clockwise after the VFD starts up when it reads 1 LED display shows reverse rotation direction ball mill operates counterclockwise 8 The cooling fan for VFD will start operating when the temperature exceeds 43 C When the working temperature of the VFD rises above 43 C the fan will turn on automatically On the opposite when the working temperature drops below 43 C it will turn off automatically 9 If the VFD is confirmed to work normally after the operations mentioned above it s then OK to continue the non load test running of the ball mill 10 Put on the protection cover of ball mill switch on the safety switch and press the operation button The operation indicator light will turn on and the ball mill will start test running 11 Press the up button and d2. 6 Press Meese to make the display blink 7 Press RUN button to make ball mill start working 8 Follow procedures in Example 2 and set rotating speed or frequency as required 9 The machine will stop automatically after 10 repeat operations Switch off and disconnect the power supply Note In operation the function code Cd16 displays countdown It this example it will display a countdown from 9 to 0 Example 5 Automatic direction reversal operation with pauses at fixed time Ball milling operation requires 0 8 hours of operation in the default direction followed by 0 5 hours shutdown and then 0 8 hours of operation in the reverse direction and finally shutdown after 20 repeats 17 Page Torrey Hills Technologies 1 Cd02 select 1 to set the operatonal method as direction reversal operation 2 Cd03 select 1 to set the operation as fixed time 3 Cd04 select 48 to set the operating time as 0 8 hours 4 Cdl4 select 30 to set the interval shutdown time as 0 5 hours 5 Cdl6 set the number to operation and restart times as 19 6 Press Mewisc button to make the display blink 7 Press IRUN button to make ball mill start working 8 Follow procedures in Example 2 and set rotating speed or frequency as required 9 The machine will stop automatically after 20 repeats Switch off and disconnect the power supply Three Trouble shooting for VFD If any abno
3. Mounting Milling Jars Immediately after milling jars are filled users can install jars inside the jar fixture It is possible to install 4 milling jars at the same time or 2 milling jars 8lPage Torrey Hills Technologies symmetrically It s not allowed to install only 1 or 3 milling jars After installation tighten circular shaped hand wheel bolt and lock nut in succession to prevent milling jars from loosening in the process of ball milling After the installation of milling jars put on the protection cover so that the ball mill can operate normally While the mill is running any occurrence of unusual noises should raise an alert and the machine needs to be shut down immediately After the mill is shut down users should check whether the milling jars have come loose and needed to be re tightened When milling is completed loosen the lock nut and the circular shaped hand wheel Pour the testing samples together with the milling balls onto the sieve accessory of this machine to separate the balls from the milled materials Before the next milling please check whether the jar fixtures have been loosened If they are users must re tighten the screws to avoid any accident III Power Setting 1 Motor Three phase 380V Please see the wiring diagram of this electrical appliance as shown in figure 5 for details The wiring of this machine has already been conducted before it leaves the factory so it shall not be changed at random
4. 2 Transmission system speed regulation by VFD The scope of frequency variation is between 0 50 60 Hz 3 Rated rotating speed Revolution sun wheel 0 260 RPM rotation milling jars 0 525 RPM The RFD displays the speed of rotation 9 Page Torrey Hills Technologies IV Description of the VFD I Technical Indexes of Frequency Converter 1 Model ND4L 2 Input Single phase 220V 10 50 60Hz 3 Output Voltage single phase 0 220V frequency 0 50 60HZ rated current 4A power 1 5KW allowed overload 150 for 1 minute 4 Data display Frequency rotating direction rotating speed voltage current error codes status 5 Requirements on ambient environment The machine must be used indoors The altitude of room where planetary ball mill is installed shall be below 1000 meters and free of corrosive gases dust and direct sun shine Ambient temperature should be between 10 40 C preferably lower than 20 C to avoid overheating Humidity of the room should be between 20 9096 without water condensation Vibration should be below 0 6G 6 Function code for the frequency converter E Default Function Function Description Set Scope M alu Cd01 Number of poles for motor 02 14 04 Operating mode Cd02 Note 0 indicates unidirectional operation and 0 1 0 1 indicates direction reversal operation Timing control Cd03 Note 0 indicates non fixed time contin
5. Technologies 3 Unique Features A ND4L planetary gear drive is manufactured with self lubricating reinforced plastics which ensures mechanical strength and reduces noises at the same time B Operation at regular intervals To prevent the property and quality of the milling materials being affected by overheating this machine could automatically work in the mode of operation shutdown reoperation C Automatic direction reversal helps to avoid agglomerates 4 Technical Parameters Model ND4L Matching milling jars Capacity capacity of individual jars 50ml 100ml 250ml 500m1 Material Stainless steel stainless steel with vacuum seal agate alumina 99 5 nylon Teflon tungsten carbide zirconia Type standard jars stainless steel vacuum jars jars with stainless steel vacuum cover used on agate nylon alumina jars etc to pump vacuum Maximum charge of milling jar Three fourths of the jar volume including milling balls Feed size 10mm depending on feed material and instrument configuration settings Milling results Up to 0 1 um Rated rotating speed Revolution sun wheel 260 turns min 10 rotation milling jars 525 turns min 10 Operation modes ND4L planetary ball mill is controlled with VFD and has a total of five operation modes 1 Normal operation with shutdown at non fixed time 2 Normal operation with shutdown at fixed time 3 Automatic direction reversal operation with shutdown a
6. TORREY HILLS MIXING EQUIPMENT TORREY HILLS TECHNOLOGIES LLC USER MANUAL 6370 LUSK BLVD SUITE F 111 SAN DIEGO CA 92121 858 558 6666 ND4L Planetary Ball Mill Manual II III IV VI VII Content Introduction Operation Procedures Power Setting Description of VFD Variable Frequency Drive Common Failures Repairs and Maintenance of Planetary Ball Mill Wiring Diagram of Planetary Ball Mill Appendix 3 8 9 10 Q2 24 24 ND4L Planetary Ball Mill Manual I Introduction 1 Purpose ND4L planetary ball mills grind or mix solid particles of different granularities and materials suspensions and pastes with both dry and wet grinding methods If a vacuum milling tank is used it will be possible to grind and mix samples in vacuum or inert gasses Through the use of this machine by many of the scientific research institutions and enterprises it has been proved that the ND series planetary ball mills manufactured by Torrey Hills Technologies LLC have the capability of grinding materials up to the nano level in some cases up to about 30 nanometers 0 03 um They are widely applied in such fields as geology metallurgy soil building materials chemical industry light industry medicine electronics porcelain battery environmental protection and so on Along with innovations in science and technologies and the wide application of nano materials mechanical alloying MA disc
7. cy stop relieve machine urgently and lock the operation control Error Error Type Possible Causes Of Error Countermeasure Code EMS Failure of exterior 1 Failed terminal of external equipment I Check the reasons for the operation of failed equipment terminal CPU Electromagnetic 1 Single Chip machine is severely interfered 1 Press STOP RESET button to reset Interference 2 Seek technical support CPUE EEPROM Failure 1 EEPROM is severely interfered in reading and writing 1 Press STOP RESET button to reset 2 EEPROM is damaged STOP Locking for 1 Double press the button STOP RESET on the panel to I Double press the button STOP RESET on the panel to relieve machine urgently and lock the operation control locking for emergency stop NOTE T In the process of ball milling the impact of milling balls on the milling jars will make the temperature of the jar rise which is a normal phenomenon and doesn t relate to the over heating protection of the frequency converter If higher temperature has an effect on the nature of the milling materials users could adopt internal operation method for ball milling or other cooling methods 2 If users could not eliminate failures of the VFD they should contact the manufacturer directly for further technical assistance V Common Failures Repairs and Maintenance of Ball Mill 1 Ball mill refusing to work Situation 1 Nothing is displayed after VFD is switched on Check if the powe
8. f decelerating operation of PG OC Overcurrent for I Voltage of the grid is on the low side I Check the input electrical source constant speed 2 Capacity of VFD is on the low side 2 Check whether the input is of phase lack operation of the 3 Reset motor when instant stop happens during starting 3 Choose VFD with matching capacity grade frequency converter period 4 Set the starting mode A GO as rotating speed 4 Load is too much tracking restart mode 5 Check the code wheel and its wiring 6 Check the load or replace the VFD with another one with bigger capacity OE 1 Over voltage for the I The input voltage is abnormal I Check the input electrical source accelerating operation of the frequency converter 2 Start up the motor non speed tracking startup 2 Set the starting mode A GO as totaling speed tracking restart mode soigo ouugoo SIIH AdIIOL o8egI0c Error Error Type Possible Causes Of Error Countermeasure Code OE 2 Over voltage for the I Time set for deceleration is too short I Adjust the decelerating time decelerating 2 Potential energy load or load inertia is relatively big 2 Connect braking resistance externally operation of the 3 The input voltage is abnormal 3 Check the input power source frequency converter OE Over voltage for I Abnormal change happens to input voltage I Install input reactor constant speed 2 Check the input power source operation of
9. lection and switch button A button for switching between the state of programming and monitoring It switches between parameter displays and programming menus If it is already operated in the state of programming menu pressing the button will return you to the previous menu 3 ENTER DATA Access the next menu while programming or save programmed operations 4 a Up button Increase to select function code menu group or set parameter values 5 RUN Start button To be used for starting VFD 12 Torrey Hills Technologies wi 6 Down button Decrease to select function code menu group or set parameter values 7 Indicator light Switch among the indications of rotating direction FIR frequency Hz rotating speed Hz v voltage v and current A by moving the green light upwards or downwards 8 aa Shift button Shift the display of rotating direction frequency rotating speed voltage and current 2 Change the digit to be modified 9 Inching button This VFD has no such function 10 Operation indicator light This light turns green when the VFD operates 11 L STOP RESET Stop and reset button Press this button to stop the operation of VFD or reset the operation in the occurrence of a failure alarm II Operating method A Test running of the VFD with no milling jars installed 1 Connect 220V alternative current to the ball mill 2 Turn on the power supply switch and LED
10. lls Technologies Figure 4 1 Belt 3 Screw 4 Hex Bolt 2 Big Pulley A Replacing belt of the motor a Lift the ball mill as shown in figure 4 b Take out the belt and replace it with O type belt A1041 accessory of this machine B Replacing gears and bearing a Unscrew the four hex bolts inside the jar fixture and take out the four fixtures one by one please see figure 1 b Lift the ball mill c Take out the belt of the motor d Unscrew hex bolt and screw in the two threaded rods M6 x 50 accessories of this machine into the screw holes to eject the big pulley slowly e Immediately after taking out the big pulley users will find 6 hex bolts After unscrewing the bolts take out the big tray and the drive from the front side of the ball mill together before changing damaged parts f After replacing the spare parts restore the ball mill in reversed steps 7 Users can always contact the manufacturer for any kind of repair and maintenance problems 23 Page Torrey Hills Technologies VI Wiring Diagram of Electrical Appliance VII Appendix 1 The manufacturer provides limited one year warranty for this machine If problems occur due to the improper operation by the users or harmful operation environment for VFD cost of parts and service fees will apply 2 Packing list Code Name Qty Remark 1 User Manual 1 2 Belt 1 O type 1041 3 Threaded rod fo
11. on reversal 2 Cd093 select 1 to set the operation as fixed time 3 Cd04 select 90 to set the alternative operating time as 1 5 hours 4 12 select 900 to set the operating time as 15 hours 5 14 set the pause time between rotations in reverse directions as 0 0 6 Cd16 set the numbers of repeat operations as 9 7 Press button to make the display blink 16 Hills Technologies 8 Press IRI tY button to make ball mill start working 9 Follow procedures in Example 2 and set rotating speed or frequency as required 10 The machine will stop automatically 15 hours later Switch off and disconnect the power supply Note In operation the function code Cd16 displays countdown It this example it will display a countdown from 9 to 0 Example 4 Uni directional operation with pauses at fixed time Ball milling operation requires 0 5 hours of operation followed by 1 hour of shutdown Then it runs for another 0 5 hours before shutting down for 1 hour again The process repeats 10 times and then the machine shuts down 1 Cd02 select 0 to set the operational method as unidirectional 2 Cd03 select 1 to set the operation as fixed time 3 Cdl2 select 30 to set the operating time as 0 5 hours 4 15 select 60 to set the interval shutdown time as 1 hour 5 CD16 set the number of operation and restart times as 9
12. overed in 1980s endows ND series planetary ball mills with new missions The basic process of mechanical alloying is that the powder or particles of several different metallic and non metallic elements are repeatedly mixed crashed and cold welded in ball mill gradually refined to nano level and form a nucleus of alloy in solid state This has made substances that are difficult to alloy using traditional melting processes be mechanically alloyed in the milling process Torrey Hills planetary ball mills have been utilized to make many kinds of alloy powders such as nano crystalline hard alloy non crystalline alloy powder and Al 03 Al compound powder 2 Operational Principles ND4L planetary ball mill consists of a revolving sun wheel and four rotating milling jars Materials are ground by the large centrifugal force generated during revolution and rotation Thus the jars containing the grinding media rotate about two separate parallel axes A planetary arm is centered at a point about which it revolves at a certain velocity The jars rotate in the opposite direction with a different velocity The drive ratio of revolution and rotation is 1 2 one circle of revolution will make two circles of rotation in the opposite direction Inside the jars the milling balls and the materials being processed impact with each other under the laws of eccentricity to break up grind and mix the testing samples 3 Page Torrey Hills
13. own button for accelerating and decelerating test of the ball mill 14 Page Torrey Hills Technologies 12 Adjust the rotating speed of the ball mill to the maximum rated rotating speed and make it operate for some time before judging if the operation sound of the ball mill is normal 13 After everything is proved normal press the stop button STOP RESET to make ball mill stop The LED will restore its blinking display 14 After about 5 seconds switch off power P OFF will appear and then disappear B Test running with milling jars installed 1 the VED and ball mill are proved normal after all of the above operations it is now OK to fill the milling jars with milling materials and milling balls Install the jars on the jar stations following instructions in section II Operation Procedures of this manual 2 Put on the protection cover switch on power and start the test running of planetary ball mill C Practical examples of operation Example 1 Unidirectional operation with shutdown at non fixed time Ball milling some testing sample with non fixed long time unidirectional operation at the rotating speed of 400 turns minute 1 Cd02 select 0 to set the operation method as unidirectional 2 Cd03 select 0 to set the operation as non fixed time 3 Press button to make the display panel blink 4 Press IRUN button to make ball mill start working 5 Press button ba till two red light
14. r maintenance 2 M6 x 50 4 Stainless steel sieve 1 24 Page Torrey Hills Technologies
15. r supply is normal first and then check if the main switch is damaged Situation 2 The VFD displays but the motor doesn t start up after the operation button is pressed Check the wiring between the VFD and the motor Also check if the cover of the ball mill is placed on correctly and if the safety switch is damaged 2 If the rotating speed of the sun wheel decreases significantly or is not even or the rotation is weak in the ball milling process most likely the driving V belt of the motor is worn and shall be replaced with the method described later 3 If abnormal noises occur abruptly in mill operation it s necessary to shut down the machine immediately and check if the milling jars are loose Tighten the bolts before restarting the ball mill 4 The noises of ball milling quiet down or disappear abruptly in the normal operation of ball mill In such conditions it s necessary to shut down the machine immediately cut the power supply and rotate the milling jars with hands If it s discovered that one or several milling jars are not able to rotate freely most likely the gears are damaged and shall be replaced 5 If metal friction noises or abnormal smells appear in the operation of ball mill it s necessary to shut down the machine immediately and cut the power supply Pull the jar fixtures with hands If they have come loose mostly likely the bearing is worn and shall be replaced 6 Tips for self repair 22 Page Torrey Hi
16. rmities occur to the VED its protection functions will start working LED will display the error code in a blinking manner and ball will stop running automatically After such errors are eliminated press MenwESC button and then restart the ball mill for operation Error Codes and Countermeasures 18 Page Torrey Hills Technologies soigo ouugoo p s H AdIIOL 2884161 Error Error Type Possible Causes Of Error Countermeasure Code OCI Overcurrent for the I Time for acceleration is set too short I Adjust accelerating time accelerating 2 V F curve or torque elevation is set up improperly 2 Adjust the V F curve or torque elevation operation of the 3 Reset VFD when instant stop happens 3 Set the starting mode A OO as rotating speed frequency converter 4 Capacity of VFD is on the low side tracking restart mode 5 There is a failure or disconnection of code wheel in the 4 Choose VFD with matching capacity process of accelerating operation of PG 5 Check the code wheel and its wiring OC2 Overcurrent for the I Time for deceleration is set too short I Adjust decelerating time decelerating 2 Potential energy load or load inertia is relatively big 2 Connect braking resistance externally operation of the 3 Capacity of VFD is on the low side 3 Choose VFD with matching capacity frequency converter 4 There is a failure or disconnection of code wheel in the 4 Check the code wheel and its wiring process o
17. s are on and display the rotation speed of ball mill wi 6 Press A Or button to adjust the speed to 400 RPM 7 After a prolonged period of operation press button STOP RESET to shut down the machine manually 8 Switch off the power supply and the milling is completed 15 Page Torrey Hills Technologies Example 2 Uni directional operation with shutdown at fixed time Ball milling to be shut down after 10 hours unidirectional operation at 40Hz frequency 1 Cd02 select 0 to set the operation method as unidirectional 2 Cd03 select 1 to set the operation as fixed time 3 Cd12 select 600 0 to set the operating time as 10 hours 4 Cd16 select 0 to set the number to repeat operation as none 5 Press to make the display panel flicker 6 Press RUN button to make ball mill start working 7 Press mm button till red light Hz display turns on The display shows the frequency A 9 8 Press A Or M button to adjust the frequency to 40Hz 9 The machine will stop automatically after 10 hours of ball milling 10 When the ball milling is completed switch off and disconnect the power supply Example 3 Automatic direction reversal operation with shutdown at fixed time Run automatic direction reversal operation and change direction every 1 5 hours and the machine will shut down automatically 15 hours later 1 Cd02 select 1 to set the operational method as automatic directi
18. t fixed time 4 Operation at regular intervals with shutdown at fixed time 5 Direction reversal operation and operation at intervals with shutdown at fixed time 4 Page Torrey Hills Technologies Speed control Frequency converter 0 50 60 Hz resolution 1 Hz speed control in terms of frequency 0 50 60 Hz Manual adjustments can be made at any time Machine programming capability 0 1 100 hours fixed time operation 0 1 50 hours fixed time automatic direction reversal operation 0 1 100 hours fixed time operation at regular intervals 0 100 times of repeat operation Power Single phase 220V alternating current AC 4A 1 5KW Net weight of ball mill 330Ib 150kg 5 Page Torrey Hills Technologies 5 Structure Sketch Lem 8 T LIE d hi MN Figure 1 6lPage Torrey Hills Technologies 1 Safety switch 11 Motor 2 Control panel 12 Machine base 3 Main pulley 13 Backcover 4 Bridging gear 14 Fixture 5 Fixed gear 15 Ball milling jar Planetary gear 17 VFD 9 Sun wheel 19 Hand wheel 10 Small pulley 20 Cooling fan Please see figure 2 for planetary ball mill working mechanism lc NND Figure 2 1 Bridging Gear 3 Fixed Gear 2 Planetary Gear 7 Page Torrey Hills Technologies II Operation Procedures 1 Examination Upon opening of the container check for damages to the planetary ball mill the power packet and the milling jars d
19. the frequency converter FTL Failure of power I Momentary overcurrent of VFD I Please refer to the countermeasure against over module 2 Inter phase or earthing short circuit of three phase current output 2 Check the output connecting line and conduct 3 The VFD is not well ventilated or the fan is broken wiring again 3 Dredge air duct or change fan 4 Seek technical support OH Overheating of I Ambient temperature fails to meet specification 1 The working environment of VFDshall meet radiator of power requirements specification requirements module 2 Ventilation of VFD is poor 2 Rectify and improve the ambient ventilation and 3 Cooling fan failure heat dissipation environment of VFD 4 Temperature testing circuit is damaged 3 Change fan 4 Seek technical support OL Motor overload I V F range setting is improper 1 Adjust V F curve 2 The voltage of the grid is too low 3 Long time operation of motor with heavy load at low speed 4 The over load protection coefficient of motor is not set properly 5 Locked operation or over load of motor 2 Check the input voltage of grid 3 Select motor specially for VFD if long term low speed operation is required 4 Set the over load protection coefficient 9 18 ofor motor correctly 5 Adjust on load working conditions or select VFD 6 Adjust the wiring of code wheel or change the direction soigo ouugoo p s H AdIIOL 82411 emergen
20. uous 0 1 0 and 1 indicates fixed time Setting time for operation at regular intervals Cd04 minutes 1 300 0 5 Cd05 Maximum frequency Hz 0 01 50 42 Cd06 Minimum frequency Hz 0 50 1 Accelerating time seconds Cd07 Time taken to increase from 0 5Hz to 50Hz 0 173600 10 Decelerating time seconds Cd08 Time taken to decrease from 50Hz to 0 5Hz 0 173600 15 Cd09 Setting of drag coefficient gear ratio 0 10 200 00 0 43 Display method 10 Note 0 displays frequency with power 1 switched on 1 displays rotating speed with 0 0 power switched on Display of direction 11 Note 0 indicates clockwise rotation and 1 0 1 0 indicates counter clockwise rotation lOlPage Torrey Hills Technologies Cd12 Fixed operating time minutes 17 999 0 Cd13 Current correction A 0 1 10 Shutdown time for direction reversal operation Cd14 minutes 0 0 999 0 Repeat operation shutdown time minutes 15 Note For unidirectional operations the shutdown 1 999 0 time between each repeat operation For repeat operation number of restarts for the dv same operation Decio lilPage Torrey Hills Technologies 7 The operation and functions of control panel Figure 3 1 LED digital display zone Display of frequency default and reverse rotating direction rotating speed voltage current failure code and function code 2 Menu se
21. uring transportation Also check whether the machine is missing accessories 2 Reading the instructions Read the User s Manual carefully Carry out non load test running of the ball mill as per the steps described in the Manual and check whether the operation of the VFD and ball mill is normal 3 Loading Jars It s now OK to load jars if the procedures above are completed a Loading milling jars To enhance the efficiency of ball milling milling balls of different sizes are loaded into the jars with bigger balls for breaking up coarse milling materials and small ones for grinding them out to the required fineness The following table shows the recommended ball charges for each milling jar of various sizes reference only Jar Volume ml 50 100 250 500 1000 Ball o6 50 100 280 500 1000 Pcs 10 8 16 40 100 200 20 2 3 Note The optimal ball charge recommendations are based on empirical data obtained by users processing milling materials of different natures to reach different required finenesses b Loading milling materials The filling level of the jar is important for successful grinding Generally a jar filling should not exceed two thirds of the jar volume The remaining third of the volume is necessary for the free movement of balls The actual grinding result depends on mill speed ball size material and grinding time You will be able to find the best combination after a few tries 4
22. will display P OFF It also displays blinking 50 00 Hz Indicator light turns on 3 Press menu selection and switch button LED will display the function code CdOr 4 Press function selection and save button LED will display the current value of the function code CdOl such as 04 If modification is necessary press A or d to set the value required After setting press the button again The value will be confirmed and saved and the next function code Cd02 will be displayed at the same time If this button is not pressed the set value will not be memorized by the VFD and the previous value will remain effective 5 Set values as necessary under each function code by repeating the procedures above It is possible to press shift button to make LED blink display the data already set so that data setting can be done more quickly 13 Page Torrey Hills Technologies 6 After setting Cd16 press the butto to confirm and the panel will display b After MN LM down button LED displays 16 If you continue pressing the button by one function code will change from Cd16 to Cd01 one Note While programming if LED displays symbols such as b R P H d and these are other functions of VFD that have Mi do with the functions of the ball mill Users only need to press the button continuously to return to Cd16
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