LABTECH ESSA

LM1-P
MODEL NO: 100100
415 VOLTS / 50 HZ

INSTRUCTION AND MAINTENANCE

MANUAL

Labtech Essa Pty. Ltd.

8 Yelland Way, Bassendean, WA 6054, AUSTRALIA
Fax: 61+(08) 9377 3420 Telephone: 61+(08) 9377 3677

Manual/standard/882027.DOC

LABTECH ESSA Model LM1-P.

INSTRUCTION MANUAL.

CONTENTS:

1. INSTALLATION REQUIREMENTS ...................................................................2

1.1. SERVICES ................................................................................................................2
1.1.1
1.1.2

Power .......................................................................................................................... 2
Pneumatic.................................................................................................................... 2

1.2. FLOOR SURFACE...................................................................................................2

2. INSTALLATION...................................................................................................3
2.1 UNPACKING.............................................................................................................3
2.2. INSTALLATION ......................................................................................................3
2.3 OPERATION CHECK ..............................................................................................4

3. OPERATION ........................................................................................................5
3.1. LOADING .................................................................................................................5
3.2. STARTING ...............................................................................................................5
3.3. STOPPING ................................................................................................................5
3.4. UNLOADING............................................................................................................6
3.5. ROUTINE PROCEDURE ........................................................................................6

4. MAINTENANCE ..................................................................................................7
4.3 PLATFORM INSERT ..............................................................................................7
4.2.1 Removal............................................................................................................................. 7
4.2.2Replacement ....................................................................................................................... 8

4.4. PNEUMATIC CLAMP .............................................................................................9

4.4.1 Removal............................................................................................................................. 9
4.4.2 Installation ......................................................................................................................... 9

4.5 MILL ..........................................................................................................................9

4.5.1 Lubrication......................................................................................................................... 9
4.5.2 Dis-assembly...................................................................................................................... 9
4.5.3 Assembly ......................................................................................................................... 11

4.6 PULVERISER HEADS AND COMPONENTS ......................................................11

5. T R O U B L E S H O O T I N G .........................................................................12
General arrangement Fig 1.....................................................................................13
Control cabinet Fig 2 ..............................................................................................15
Millmate assembly Fig 3..........................................................................................16
Swivel cradle assembly Fig 4...................................................................................17
Electrical circuit Fig 5.............................................................................................19

PAGE 1

1. INSTALLATION REQUIREMENTS
1.1. SERVICES
1.1.1 Power
a) Supply: 380V, 3 phase, 50 Hz
b) Consumption: < 1100 W. per unit.

1.1.2 Pneumatic
600-700 kPa (85-100psi) at 1 litre/min (0.1CFM) minimum
required
flow.

1.2. FLOOR SURFACE.

The LM1-P is designed to be securely fastened to a concrete floor using the high
stress fasteners provided.

NOTE:

Where the LM1-P is to be used in a location not having a concrete

floor, it is recommended that it be mounted on a reinforced concrete
slab measuring 1m x 1m x 100 mm (3'6" x 3'6" x 4").

1.3 FLOOR SPACE.

The minimum clearances for lid opening and operator access are:
Rear:

400 mm (16")

R.H. (Control Panel) side:

350 mm (14")

L.H. side:

10 mm (3/8")

Front:

1 m (3'6")

PAGE 2

2. INSTALLATION
2.1 UNPACKING
The LM1-P is delivered on a pallet, fully assembled and interconnected. For ease of
installation, unpack at the installation site.
a)

Cut bands, remove exterior packing and visually inspect for damage.

NOTE:
Should any damage be evident, notify the carrier immediately. In
addition, advise Labtech Essa of nature and extent of damage to minimise
delays in repairs.
b)

Disconnect the 6mm pneumatic tube from side of mill. (Simultaneously,

press lock release ring and pull the tube).

c)

Remove four hex head screws securing the sound reduction cabinet to
the base frame. Locations: 2 front, 2 rear.

d)

Untie power cable from top of mill.

e)

Carefully lift sound reduction cabinet from Mill and place alongside. Avoid
stressing the power cable.

f)

Unbolt mill from pallet.

g)

Lift mill and remove mounting frame. (Fig. 1, item 10).

2.2. INSTALLATION
a)

Using the mounting frame as a drilling jig, drill floor using 16 mm (5/8")
masonry drill to depth of 75 mm.

b)

Secure mounting frame and mill to floor.

c)

Position sound reduction cabinet over mill and secure to frame with four
hex head screws.

d)

REMOVE TRANSPORT LOCKING MATERIAL.

(3 bolts, nuts and spacers installed equidistant around mill platform - Fig.
1, item 2).

e)

Connect 6mm pneumatic tube to mill. Push into fitting, pull lightly to
ensure tube is secure.

f)

Connect pneumatic supply.

g)

Connect 3 phase supply.

h)

CHECK TENSION OF FLOOR MOUNTING BOLTS AFTER ONE WEEK

OF ROUTINE OPERATION.

PAGE 3

2.3 OPERATION CHECK

** CAUTION **
UNDER NO CIRCUMSTANCES ATTEMPT TO OPERATE THE LM1-P WITH
COMPLETE HEAD AND COMPONENTS INSTALLED, WITHOUT AN ADEQUATE
CHARGE IN THE HEAD.
The required charges for Labtech Essa heads are:
B 2000
B 1000
B 800
B 300/400
B 125

200 - 2000 ml.

100 - 1000 ml.
50 - 800 ml.
50 - 300 ml.
10 - 120 ml.

a)

Select a pulveriser head and components, add the cleaning charge and
install in mill.

b)

Leave lid open. Set timer (any time), and press ON (Green) button.

NOTE: Ensure pneumatic clamp does not operate and mill does not start.
c)

Lower lid. Press ON button and hold until mill starts. (If mill does not
start, refer to section 5, Troubleshooting).

d)

Before Timer times out, press STOP (red) button.

NOTE: Ensure mill stops and pneumatic clamp air bleeds off over a period of 3
to 5 seconds.
e)

Re-start mill. Lift lid.

NOTE: Ensure mill stops and pneumatic clamp releases.

f)

Lower lid. Set Timer for a short time and start Mill.

g)

Allow Timer to time out and ensure mill stops.

h)

The LM1-P is now ready for routine operation.

PAGE 4

3. OPERATION
NOTE:
1.

The choice of pulveriser head and size of sample to be prepared are to be in

accordance with the Sample Preparation Specifications detailed by the
laboratory supervisor.

2.

A general procedure calls for cleaning pulveriser head and components

between samples, by grinding quartz or other specified material. The minimum
quantities to be used in Labtech Essa pulveriser heads are:
B 125
B 300, B 400, B 800
B 1000
B 2000

10 ml.
50 ml.
100 ml.
200 ml.

For other heads, observe manufacturers recommendations.

3.

Ensure Labtech Essa B 2000 grinding discs are installed top uppermost. The
top is marked.

3.1. LOADING
a)

Add material to be pulverised to the selected head with rings and roller or
pulverising disc, and ensure lid fits squarely on head.

b)

Lift cabinet lid and position head under clamp.

c)

Check head is firmly and squarely seated.

d)

Close cabinet lid.

3.2. STARTING
a)

Ensure power is ON.

b)

Ensure pneumatic supply is connected.

c)

Set Timer to time specified in procedure.

d)

Press ON (Green) button.

3.3. STOPPING
The LM1-P may be stopped by:
a)

Waiting for Timer to time out.

b)

Lifting the cabinet lid.

c)

Pressing the STOP (Red) button.

NOTE: The mill will also stop should the power or pneumatic supply fail.

PAGE 5

3.4. UNLOADING
Wear gloves when unloading. Efficient operation of the LM1-P imparts heat to the
pulveriser head and contents.
a)

Stop the mill.

b)

Wait for pneumatic clamp to release.

c)

Lift cabinet lid.

d)

Ease heads up and forward to remove.

e)

Remove material from head per procedures specified by the laboratory

supervisor.

NOTE: When using a pulverising disc, use hook provided to remove from bowl.

3.5. ROUTINE PROCEDURE

a)

Twice daily, or as ambient conditions demand, press drain button on air

inlet filter bowl (at base of control panel) to expel water.

b)

Weekly: Inspect all head lid seals and replace as required to minimise
sample loss and creation of airborne dust.

c)

Monthly: Inspect platform insert in centre of mill platform. Replace as

required.

d)

Check that Mill is tightly secured to the floor with the mounting bolts.

PAGE 6

4. MAINTENANCE
NOTE:

1.
2.

4.1. ELECTRICAL

To ensure a continuing reliability of the LM1-P refers all

maintenance procedures to qualified personnel.
The following text identifies items in all figures, in the form
(1/4) The example (1/4) refers to figure 1, item 4.

(Refer Figure 5)

Maintenance of the electrical control circuit of the LM1-P requires no routine attention
other than periodic cleaning. Until experience of the specific conditions of use
indicate a more or less frequent cleaning, it is recommended that the cover be
removed from the Control Unit and the circuit be vacuum cleaned once every three
months.
a)

Thermal overload:Set for - Automatic Reset

-Full load Current as noted on the Motor specification
plate.

b)

Lid Interlock: Safety Switch. If prong is not engaging adjust with a suitable
amount of sheet metal spaces.

4.2. PNEUMATIC (Refer Figure 4)

The pressure required to operate the LM1-P is 500 kPa to 700 kPa (85/100psi) at 1
litre per minute (0.1CFM) minimum required flow rate.
a)

Routine maintenance of the pneumatic control circuit is restricted to

periodic replacement of the cintered filter and inspection of components
for corrosion damage.

NOTE: As the amount of water present in the pneumatic supply is

related to atmospheric conditions and the configuration of the
supply compressor/drier, the time interval for filter insert
replacement is a matter for user judgement.

4.3 PLATFORM INSERT

The Platform Insert (1/29) provides protection against abrasion between the
pulveriser head and the mill platform. It is important that the insert be in good
condition. The insert should be replaced when wear on the load-bearing surface
exceeds 2 mm.

4.2.1 Removal
Lever the insert out, using a thin blade screwdriver between the outer edge of
the insert and the mill platform.

PAGE 7

4.2.2Replacement
a)
b)
c)

Ensure the mill platform is clean.

Place the insert in the platform so that the majority of the insert lip is in
place.
Using a soft-faced hammer, tap insert firmly into place.

PAGE 8

4.4. PNEUMATIC CLAMP

4.4.1 Removal.
a)

Uncouple Connecting Pipe (1/26).

b)

Remove Plastic Blanking Plugs from top of Platform assembly.

c)

Remove socket head screws, accessible through holes exposed by

removal of plastic Blanking Plugs and remove Pneumatic Clamp (1/24).

d)

Remove Elbow (1/28).

4.4.2 Installation
a)

Apply thread sealant and install Elbow (1/28).

b)

Secure Pneumatic Clamp (1/24) to Platform assembly with socket head

screws.

c)

Insert Rubber Banking Plugs.

d)

Couple Connection Pipe (1/26).

4.5 MILL
Access to the Motor, Eccentric Mass and Bearings is achieved by removal of
the complete Platform/Motor assembly from the Frame.
** CAUTION **
THE WEIGHT OF THE MILL PLATFORM/MOTOR ASSEMBLY IS SUCH THAT
MECHANICAL LIFTING ASSISTANCE OR THE EFFORT OF TWO PERSONS IS
REQUIRED.

4.5.1 Lubrication
It is recommended that all bearings be inspected and lubricated at two year intervals.
To do this, it is necessary to dis-assemble both the mill and motor.
NOTE:

FOR LUBRICATION, USE MAINLUBE 340 GREASE.

4.5.2 Dis-assembly.
a)

Disconnect power.

b)

Disconnect 6 mm Air Hose (1/14) from frame by simultaneously pressing

lock release ring and pulling on hose.

c)

Remove cover from Control Box (2/15).

PAGE 9

d)

e)

Disconnect motor power cable from Thermal Overload (2/4) terminals 2, 4

and 6, and from Earth stud. Loosen screws in Cord Lock Grommet and
pull cable through to inside of cabinet.
Remove and retain four screws securing cabinet to Mounting Frame
Assembly (1/10).

f)

Lift off Cabinet (1/4) and place aside.

g)

Loosen Cable Gland nut and feed sufficient cable through to enable
removal of platform/motor assembly.

h)

Lift Platform/Motor assembly (1/21), and at the same time rotate the
springs (1/1) to ease removal of the Platform.

i)

Lift the Platform/Motor assembly clear and support in an upside down

position.

j)

Remove and retain the six socket head cap screws securing the Motor
Flange (1/8).

k)

Lift Motor/Mass assembly clear of Platform (1/7) and place aside. Two
jacking screw holes, to accept the screws removed in (j), are provided to
facilitate separation.

NOTE: Protect components of Mass Support Bearing (1/5 a & b) from

contamination.
l)

Remove and retain grub screw from Eccentric Mass assembly.

m)

Separate Eccentric Mass from Motor.

NOTE: Remove and retain Key.

n)

Remove and retain four socket head cap screws securing Motor End
Plate to Motor Body (1/11).

o)

Separate Motor End Plate from Motor Body. Remove and retain four
socket head cap screws securing Fan Cowling, and remove Cowling.

p)

Drive out pin securing Fan and press off Fan. Remove Rotor from Motor.

q)

Clean all motor components and inspect for serviceability. Pay particular
attention to bearings and seals.

r)

Clean and inspect Mass Support Bearing (1/5 a and b) and Seal (1/6).

s)

Replace faulty items. Assemble bearings and seals with a good quality
sealant, with exception of motor floating bearing (fan end).

NOTE: To replace Mass Support Bearing (1/5) and Seal (1/6):

- Remove Platform insert (1/29).
- Locate and remove threaded plugs in Platform (1/21).
- Press out items 5 a & 6.
- Assemble Bearing and seal with a good quality sealant.

PAGE 10

Replace threaded plugs in platform using a thread sealant.

BE CAREFUL NOT TO TIGHTEN THREADED PLUGS

INTO BEARING
4.5.3 Assembly
NOTE: To protect against bolts and screws loosening as a result of vibration
during operation, assemble all threaded components with a high quality
thread locking compound applied to the threads.
a)

Lubricate all bearings, shafts and seals with MAINLUBE 340 grease.

b)

Assemble in reverse order to Dis-assembly

c)

When assembling the Eccentric Mass (1/7), ensure the Key is correctly
installed.

d)

Tension the grub screw in the Eccentric Mass Assembly to 15-20 Nm.

e)

When mounting the Platform/Motor assembly on the springs (1/1), ensure

the Platform is fully seated on the springs.

f)

When bringing motor power cable through Frame cable gland, ensure
sufficient cable slack remains inside frame to prevent stressing cable
during operation. Be careful to also ensure cable is not so slack as to be
in contact with the frame or floor; a condition which could result in friction
damage to the insulation of cable.

g)

Overload:
Unscrew terminals fully to give maximum opening to receive
wires.
Ensure wire is fully and firmly clamped in the terminal.

h)

Secure motor earth to Control Unit Earthing Stud.

Procedure.

4.6 PULVERISER HEADS AND COMPONENTS

All heads, rings, rollers, pulveriser discs and seals are subject to wear
determined largely by the material under preparation.
REGULAR INSPECTION IS ESSENTIAL
a)

Change lid seals as soon as damage or permanent deformation is

evident.

b)

Unusually rapid wear of any head component should be referred to

Labtech Essa for advice.

PAGE 11

5. T R O U B L E S H O O T I N G
PROBLEM

POSSIBLE CAUSE.

Mill will not start

Power not supplied.

Electrical contactor faulty.
Thermal overload tripped or faulty.
Wiring to motor faulty.
Start switch faulty.
Air not supplied.
Air pressure switch faulty or set incorrectly.
Cabinet Lid open.
Timer not set or faulty.
Faulty lid safety switch.
Airbag leak.
Faulty solenoid valve.
Water contamination of air circuit has damaged pneumatic
components.

Mill intermittently stops prematurely

Inadequate pneumatic supply.

Water damage to pneumatic components.
Wiring fault - intermittent contact.
Thermal overload not set to correct current or faulty.
Mis-aligned lid safety switch.

Loss of sample

Faulty bowl seals or no seals installed.

Worn abrasion resistant pad.
Water damage to bleed regulator.

Head gets very hot

No fault. This condition indicates efficient operation. If head is

too hot to handle, the indication is that your application
requires two or more heads so that cooling may occur.

PAGE 12

General arrangement Fig 1

PAGE 13

PARTS LIST

MILL MODEL LM1-P

DIAG NO

PART NO

DESCRIPTION

470015
340028
340042
340012
111060
111044
111039
340042
340012
340028
340189
111062
111054

Disc Hook
Connector
Bulkhead Fitting
Air Hose
Cabinet hinge
Cabinet Lid
Flexible Air Hose
Bulkhead Fitting
Air Hose
Connector
Elbow
Platform Adaptor Plate (Square)
Platform Adaptor Plate (Round)

PAGE 14

Control cabinet Fig 2

PAGE 15

Millmate assembly Fig 3

PAGE 16

Swivel cradle assembly Fig 4

PAGE 17

MILLMATE SPARE PARTS

DIAG NO

PART NO

DESCRIPTION

111042
340041
340029
340012
340024
340002
340003
340022
111015
513510
511035
221018
521022
521015
340027
521021
111017
521027
350006
340014
340056
350020
111020
111021
524305

Millmate Assembly
Tee Fitting
Connector
Air Hose
Elbow Connector
Filter Regulator
Pressure Gauge
Elbow
Base Frame
Bolt Set
Swivel to Post Bolt Set
Swivel
Swivel Bolt Set
Air Bag Clamp Bolt Set
Connector
Millmate Lift Arm Bolt Set
Millmate Lifting Arm
Millmate Lift Arm Front Bolt Set
Shackle
Air Hose
Valve
Plastic Cap
800 Cradle Adaptor
1000 Cradle Adaptor
Bolt Set

PAGE 18

Electrical circuit Fig 5

PAGE 19

NOTES:

PAGE 20