06 Ba Exakt 80eplus Englisch

Table of Contents
THREE ROLLER MILL
Operating Instructions
Article number:
27891EN
Document number / Edition

27891EN-900-02 / Edition 02/2017 EN Translation of the original operating instructions, English
27891EN-900-02 / Edition 02/2017 1
Table of Contents
1 TABLE OF CONTENTS
1 Table of Contents 1
2 Contact addresses 6
2.1. Manufacturer address 6
2.1.1. Imprint 6
2.2. Service and ordering spare parts 6

3 Installation information in advance 7
4 Safety 8
4.1. General information concerning safety 8
4.2. Safety symbols 9
4.3. Graphical conventions 10
4.4. Commissioning 11
4.5. Selection of location 11
4.6. Safety notes regarding operation 12
4.7. Safety notes regarding cleaning work 15
4.8. Handling chemical substances and coolants/lubricants 16
4.9. Cleaning agents 17
5 Performance specifications 18
5.1. Intended use 18
5.2. No release for work in potentially explosive atmosphere 19
5.3. Reasonably foreseeable misuse 19
5.4. Qualification of the personnel 19
5.5. Technical condition 20
5.6. Protection against unintentional start 20
5.7. Safety devices 20
5.8. Safety warning notes 20
5.9. Marking 21
5.9.1. Type plate of the machine 21
5.9.2. Type plate of operating unit 23

6 Technical data 24
6.1. Environment 24
6.2. Operating and auxiliary materials 24
6.3. Weights 24
6.4. Airborne sound emission 25
6.5. Dimensions 25
6.6. Dimensions Crate 25
6.7. Electric values EU 25
6.8. Electric values US 25
6.9. Electric values Japan 25
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Table of Contents
6.10. IP protection 26
6.11. Roller temperature control 26
6.12. Rollers 26
7 Unit description 27
7.1. Functional principle 27
7.2. Overview 28
7.2.1. Section view 28
7.3. Operating modes 29
7.3.1. Cleaning 29
7.3.2. Mixing 29
7.3.3. Gap-Gap 29
7.3.4. Gap-Force 30
7.3.5. Force-Force 30
7.4. Emergency stop 31
7.5. Safety devices 32
7.5.1. Cleaning 32
7.5.2. Routine operations 33
7.6. Safety marks 34

7.6.1. Danger of crushing 34
7.6.2. Danger of cuts 34

7.6.3. Voltage 35
7.6.4. Increased leakage current 35
7.6.5. Tempering fluid 36
7.7. Control elements 37
7.7.1. Front side 37
7.7.2. Backside 38
7.8. Roller temperature control 39
7.8.1. Pressureless cooling 40
7.8.2. Pressure cooling 42
7.9. Scraper system 43

7.10. Load traverse 43
7.11. Scope of delivery 44
7.12. Equipment variants 47
7.13. Safety devices nip gap and optional accessories 48
7.13.1. Safety devices 48
7.13.2. Optional accessories 49
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Table of Contents
8 Transport 51
8.1. Packaging symbols 51
8.2. Intermediate storage 52
8.3. Uncrating 52
8.4. Instructions for lifting 55
8.4.1. Moving the machine by hand 57
9 Installation 58
9.1. Setup site 58
9.2. Dismounting the load traverse 60
9.3. Mounting and aligning the operating unit 61
9.4. Connecting the electric supply 62
9.4.1. Network configuration 62
9.4.2. Connect variant 1: fixed connection 63
9.4.3. Connection variant 2: fixed connection with coded heavy
duty connector 64
9.4.4. Connection variant 3: Connection via three-poles standard

plug (min. 15A) 66
9.5. Connecting the roller temperature control 68

9.5.1. Temperature control unit 68
9.5.2. With pressureless cooling 69

9.5.3. With pressure cooling 70
9.6. Checklist installation 70
10 Setup 71
10.1. Cleaning the machine housing 71
10.2. Scraper knife types 72
10.3. Mounting the scraper knife 73
10.3.1. Combination scraper knife – scraper bar - adaptor 75
10.4. Putting on the knife guard 76
10.5. Adjusting the scraper contact pressure 77
10.6. Mounting the scraper socket 78
10.7. Aligning the scraper socket in parallel to the roller 80
10.8. Setup of the scraper angle 81
10.9. Mounting the splash tray 82
10.10. Mounting the cleaning guard 83
10.11. Inserting plastic guides for working width 85 mm and 170 mm 85
10.12. Mounting plastic guides for working width 200 mm 87
10.13. Mounting the safety device nip gap, working widths 85 mm, 170 mm,
200 mm 90
10.14. Mounting hopper for working width 170 mm 91
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Table of Contents
10.15. Mounting hopper for working width 200 mm 93

10.16. Mounting splash guards for working width 200 mm 94
10.17. Mounting splash guards for inner side paneling 95
10.18. Mounting the solvent dispenser for guide lubrication 96
11 Operating elements and operating unit 97
11.1. Main switch 97
11.2. Operating panel 98
11.3. Emergency stop button 99
11.4. Operating unit 100
11.4.1. Safety messages on the display 102
11.4.2. Overload messages on the display 104
11.5. Program structure 105

12 Operation 106
12.1. Switching on the machine 108
12.2. Cleaning the rollers 110
12.2.1. Pre-cleaning the rollers 110
12.2.2. Preparing for cleaning 110

12.2.3. Cleaning roller 1 112
12.2.4. Cleaning roller 2 and roller 3 112
12.3. Cleaning the scraper system 113

12.4. Temperature control of the rollers 113
12.5. Adjusting the rollers 114
12.6. Defining the pre-settings (setup) 115
12.6.1. Setup after every adjustment and before each programming 116
12.6.2. Select setup via menu item Select setting (in routine
operations) 117
12.7. Routine operations 119

12.8. Routine operations: Test run with petroleum jelly 121
12.8.1. Step 1 121
12.8.2. Step 2 121
12.8.3. Optimum product flow 122

12.9. Reverse function 124
12.9.1. Sequence from the cleaning mode 124
12.9.2. Sequence from routine operations 126
12.10. Checking the safety devices 127
12.10.1. Preparing for check 127
12.10.2. Checks functions 127
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Table of Contents
13 Maintenance 128
13.1. Cleaning the machine housing 129
13.1.1. Cleaning the display of the operating unit 129
14 Maintenance and care 130
14.1. Service and maintenance plan 131
15 Troubleshooting 133
16 Shutting down 136
16.1. Short-term shutting down 136
16.2. Long-term shutting down 136
16.3. Putting out of operation 136
17 Disposal 137
17.1. Disposing of packaging 137
17.2. Disposing operating materials and cleaning agents 137
17.3. Disposing of unit 137
18 Spare and wear parts 138
18.1. Wear parts 80S Plus, 80E Plus 138
18.2. Spare parts 80S Plus, 80E Plus 141
19 Conformity check 144
19.1. Checking the conformity 144
20 Index 145
21 Annex 148
21.1. Warranty conditions 148
21.2. Declaration of conformity 149
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Contact addresses
2 CONTACT ADDRESSES
2.1. MANUFACTURER ADDRESS
EXAKT Advanced Technologies GmbH

Robert-Koch-Strasse 5
22851 Norderstedt
Germany
Phone: +49 (0) 40 / 529 560 - 0

Fax: +49 (0) 40 / 5 24 99 59
email: info@exakt.de
http://www.exakt.de
2.1.1. IMPRINT
© EXAKT Advanced Technologies GmbH, Norderstedt
Layout:: EXAKT Advanced Technologies GmbH

Text layout: EXAKT Advanced Technologies GmbH
Illustrations: EXAKT Advanced Technologies GmbH
This documentation is copyrighted by EXAKT. Without prior written approval,
the documentation may not be copied or be used contrary to the legitimate
interests of EXAKT.
Subject to change without notice!
2.2. SERVICE AND ORDERING SPARE PARTS
In case of service questions and for ordering spare parts, please contact the
retailer by whom you purchased the unit.
For ordering spare parts, use the order form in chapter 18 Spare
and wear parts.
6 27891EN-900-02 / Edition 02/2017

Installation information in advance
3 INSTALLATION INFORMATION IN ADVANCE
The installation information in advance shall give you all information you need
for preparing you site before the machine is delivered to you. It gives information
how to handle and transport the machine, information for the setup site and
electrical connection / preparation, etc.
For this, the relevant chapters in this operating instructions are shown in the
table below:
We additionally recommend to read the entire operating

instructions before the machine is delivered to you.
Especially when Chapter

ordered option
(article-no.)
4 Safety
5.1 Intended use
5.2
No release for work in potentially explosive
atmosphere
5.9.1 Type plate of the machine
6 Technical data
7.6 Safety marks
8 Transport
9.1 Setup site
9.4 Connecting the electric supply
27106 & 27107 9.4.3 Connection variant 2: fixed connection with
or coded heavy duty connector
27108 & 27109
9.5 Connecting the roller temperature control
27510 9.5.2 With pressureless cooling
27500 9.5.3 With pressure cooling
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Safety
4 SAFETY
Link back to chapter 3 Installation information in advance
4.1. GENERAL INFORMATION CONCERNING SAFETY
Every persons appointed to install, commission, operate, maintain and service

the unit and the associate components must have read and understood these
instructions and in particular the chapter Safety.
If necessary, special training appropriate to the professional qualification of the
persons in question shall be carried out.
Explanation of the symbols in these instruction:
DANGER
Indicates an exceptionally severe danger situation. Disregarding
this note will cause lethal or severe irreversible injuries.
WARNING
Indicates an exceptionally severe danger situation. Disregarding
this note can result in lethal or severe irreversible injuries.
CAUTION
Indicates a danger situation. Disregarding this note can cause
light or medium injuries.
NOTE
Indicates risk of property damage. Disregarding this note can cause
property damage.
Here you find important background information and

explanations within the current context and status information
within a sequence of action.
8 27891EN-900-02 / Edition 02/2017

Safety
4.2. SAFETY SYMBOLS
Symbol Meaning
Warning of general and not categorized risks
Warning of voltage
Warning of rollers rotating reversely
Danger of cuts
Hot surface
Suspended load
Danger of hand injuries
Danger of crushing
Danger of tripping
Warning of toxic substances
Warnung of explosive substances
Symbol Meaning
Use a spatula
Wear safety gloves
Wear foot protection
Wear eye protection
Wear protective clothing
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Safety
Wear protective apron / lab coat
Disconnect machine from the mains
Read operating instructions
Reference to other documents
4.3. GRAPHICAL CONVENTIONS
Symbol Meaning
Tool This symbol indicates that a
special tool or consumables are
required.
 Bulleted list Properties of the unit or
individual components are listed
in bulleted lists.
1. Operating Operating sequences instruct
sequence
› you to perform something in a
given sequence.
Disposal Notes for disposal of packaging
materials, wear parts and
defective unit parts.
Screwing tight CW
Clockwise
(tightening the screw)
CCW
Counterclockwise (undoing the
screw)
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Safety
4.4. COMMISSIONING
The unit housing contains information signs that additionally enable safe
operation.
Observe all safety instructions without fail, observance serves your safety.
Prior to commissioning the unit, the operator must ensure that all safety-related
conditions are met.
Adhere to the relevant accident prevention regulations as well as other generally
accepted safety-related and occupational-medical regulations.
4.5. SELECTION OF LOCATION
The unit must be placed horizontally.

The installation location must ensure safe stand of the unit.
Place the unit on a fixed lab table that can bear the weight of the machine (see
chapter 6 Technical data).
NOTE
› Do not place any items on the unit.
› Before connecting the unit, check mains cable and power plug for damage.
› Connect the unit to the connection voltage specified on the type plate.
› Before connecting, compare the mains voltage to the unit voltage given on
the type plate of the unit.
› Only allow a trained electrician to connect the machine.
When selecting the location of installation, observe the corresponding safety

notes and manufacturer specifications for the operating materials used and/or
located in the surroundings of the unit.
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Safety
4.6. SAFETY NOTES REGARDING OPERATION
Refrain from any operation that:

› constitutes a danger for life and limb of the user or third parties,
› implies impairment of the unit or other property,
› impairs the safety and the functionality of the unit,
› disregards the specified safety instructions.
Maintenance and upkeep of the machine is only allowed to be carried out by
personnel trained and certified by EXAKT. These personnel must be familiar
with the machine and instructed on its dangers as well as have the required
qualification.
WARNING
Keep the machine housing closed during operation and only
open it to rectify functional faults and to perform maintenance
tasks.
Missing safety devices and covers must be attached again
immediately after finishing the work.
WARNING
Danger of injury in the area of the rotating rollers for persons
with long hair and/or wearing loose clothing, ties, scarves,
jewelry, bracelets, etc., in particular at the product nip gap
(gap 1)!
› Always use suitable safety devices.

› For all works, wear tight-fitting clothes and protect long hair by
headgear.
› Never wear ties, scarves, jewelry, bracelets, etc. for any work.
12 27891EN-900-02 / Edition 02/2017

Safety
WARNING
Danger of being pulled in by the rollers:
During operation, the rollers of the machine are driven.
This causes a danger of being pulled in.
› When working at the machine, pay attention to your hands and
fingers.
› For cleaning, set up the cleaning plate and change into cleaning
mode.
› Only use the machine with the provided safety devices.
› In routine operation, always work with the limiting jaws inserted to
the correct working width (according to the selected safety
device).
› In routine operation, supply or remove product only with the
spatula.
› Only use one-part spatulas or riveted spatulas with long handle.
› ALWAYS keep the spatula as far away as possible from gap 1
(nip gap roller 1 and roller 2).
WARNING
Danger of scalding:
Danger of scalding or burns at the media and at hot machine parts
when handling hot temperature control media.
› Before handling temperature control media, let them cool down.
› Wear safety gloves and protective clothing.
WARNING
Danger of eye injuries due to rotating rollers or when handling
product and cleaning agents
› In general, wear eye protection
› Wear suitable protective clothing
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Safety
CAUTION
Danger of cuts at the scraper knife.
› During assembly and handling, always work with plastic knife
protection or with knife protection for scraper socket.
› When working with the scraper socket and scraper knife, wear
suitable safety gloves.
CAUTION
Danger arising from the substances to be processed:
The substances to be processed can cause health hazards.
› Read the safety datasheets of the substances to be processed
carefully.
› Wear suitable protective clothing.
DANGER
When working at live connections, disconnect the machine from
the mains.
Inattentiveness can cause an electric shock.
When performing maintenance work at the electric system,
observe the following issues:
1. Switch off the voltage of the unit.
2. Secure against being switched back on.
3. Check that it is de-energized.
4. Earth and short circuit.
5. Cover neighboring live parts and secure danger area.
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Safety
4.7. SAFETY NOTES REGARDING CLEANING WORK
WARNING
fingers.
mode.
CAUTION
CAUTION
carefully.
NOTE
› When using cleaning agents, provide sufficient ventilation.
› Observe the safety data sheets of the substances to be processed.
› Observe the disposal instructions by the respective manufacturers.
› Observe local safety regulations.
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Safety
4.8. HANDLING CHEMICAL SUBSTANCES AND

COOLANTS/LUBRICANTS
When handling oil, grease and other chemical substances, observe the
corresponding safety data sheets and disposal instructions by the respective
manufacturers and take all local safety requirements into account.
CAUTION
When handling chemical substances such as cleaning agents,
cooling and temperature control media can cause hazards in
case of contact with skin or eyes as well as inhalation.
Provide suitable exhaust and wear safety goggles, safety gloves
and protective clothing.
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Safety
4.9. CLEANING AGENTS
When using cleaning agents, observe the corresponding safety data sheets and
disposal instructions by the respective manufacturers and take all local safety
requirements into account.
WARNING
Use of explosive or easily flammable cleaning agents constitutes
an increased danger of explosion.
Do not use explosive or easily flammable cleaning agents!
27891EN-900-02 / Edition 02/2017 17

Performance specifications
5 PERFORMANCE SPECIFICATIONS
5.1. INTENDED USE
Intended use of this machine is only defined for the fields of industry,
development, research and production for the quantities specified in the
technical data. Any other use is considered improper.
The spectrum of applications reaches from food industry to nanotechnology.
The unit is suitable for processing products in cosmetics, paints, electronics,
food, dental, ceramics, lubricants, adhesives, soap and special industries.
The intended use of the machine is the reduction of particle size and
dispensation of agglomerates, in rare cases the reduction of the primary particle
size.
Changes to the machine and its accessories are not permitted.
The machine is designed for operation by only one instructed person.
Only wear and spare parts approved by the manufacturer may be used.
Any use beyond the proper use specified above is considered improper. The
manufacturer is not liable for personal injury or material damage resulting from
use of the machine for other than the intended purpose.
18 27891EN-900-02 / Edition 02/2017

5.2. NO RELEASE FOR WORK IN POTENTIALLY

EXPLOSIVE ATMOSPHERE
The machine has not been designed for use in potentially explosive areas.
› Do not operate the machine in potentially explosive atmosphere.
› Do not process any potentially explosive products.
› Do not use explosive operating materials or cleaning agents.
5.3. REASONABLY FORESEEABLE MISUSE

This includes misuse.
It is prohibited
› To store installation materials, tools and other objects on the machine during
operation.
› To install spare parts or accessories not approved by the manufacturer.
› To bypass components or functions of functional safety.
› To dismount components of functional safety or to replace them by those not
approved by the manufacturer.
› To modify components.
› To operate the machine beyond the specified service life.
› To operate the machine in potentially explosive areas.
› To disregard safety data sheets.
5.4. QUALIFICATION OF THE PERSONNEL

Unqualified personnel cannot recognize the machine's behavior and thus any
risks arising from the machine; hence they are subject to increased hazard.
› Appoint a responsible machine operator. Only hand out keys and passwords
to the appointed personnel.
› Only sufficiently qualified personnel must perform the tasks described in these
operating instructions.
› Make sure that the personnel meet the local laws and regulations for safe
work.
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5.5. TECHNICAL CONDITION

If the machine is in a bad technical condition, both good function and safety are
at risk.
› Use the machine in technically good condition only.
› Observe the maintenance intervals.
› Rectify any machine faults if the usual behavior of the machine changes.
› Rectify faults immediately.
› Do not modify the machine without manufacturer's approval.
5.6. PROTECTION AGAINST UNINTENTIONAL START

By attaching a padlock at the main switch you can secure the machine against
unauthorized use.
5.7. SAFETY DEVICES

If safety devices do not function correctly, persons are at risk.
› Make sure that all safety devices are functional before operating the machine.
5.8. SAFETY WARNING NOTES

If safety warning notes are unreadable, persons are at risk.
› Do not remove or cover safety warning notes.
› Replace unreadable safety warning notes.
20 27891EN-900-02 / Edition 02/2017

5.9. MARKING
5.9.1. TYPE PLATE OF THE MACHINE
For identification purposes, the machine is equipped with an individual label:
Article Voltage Description / Sign on

number type plate
27100 380- Solidly grounded

420VAC Wye
50Hz 3 / N / PE (5 lines)
EU, (…) TN-S / TN-C-S / TT
Fig. 1: Type plate of the machine 380-420V – Solidly grounded Wye

number type plate
27101 200- Solidly grounded
240VAC Wye
50-60Hz 3 / PEN (4 lines)
USA,
(CN)
Fig. 2: Type plate of the machine 200-240V Solidly grounded Wye
27891EN-900-02 / Edition 02/2017 21


number type plate
27105 200- Corner grounded
240VAC Delta (3 lines)
50-60Hz
Japan,
(USA)
Fig. 3: Type plate of the machine 200-240V – Corner grounded Delta
NOTE
Danger of machine damage.
The specification for voltage, frequency, and power consumption can vary
depending on the version.
Only the information on the original type plate are valid.
22 27891EN-900-02 / Edition 02/2017

5.9.2. TYPE PLATE OF OPERATING UNIT

For identification purposes, the operating unit is equipped with an individual
label:
Fig. 4: Type plate of the operating unit
The type plate on the operating unit identifies ONLY the

operating unit and not the machine! Observe the type plate of the
machine.
27891EN-900-02 / Edition 02/2017 23

Technical data
6 TECHNICAL DATA
Description Value Unit
6.1. ENVIRONMENT
Ambient temperature 10 .. 40 °C
50 .. 95 °F
Relative humidity, non condensing max. 85 %
6.2. OPERATING AND AUXILIARY

MATERIALS
Cooling / tempering fluid (thermofluid)
Operation of the machine only with circulation cooling
with a corrosion-protection/water mix.
Recommended corrosion protection:
® ® 1:4 % vol.
Glysantin G48 , mixing ratio
Medium temperature 10 .. 55 °C
50 ..130 °F
Lubricant for plastic guides
Lubricant Product-
compatible
liquid
Lubricant for toothed wheels
Grease recommendation BP Energrease LS-EP 2
Lubricant for rotary transmission leadthrough

(pressure cooling)
Grease recommendation OKS 432
(www.oks-germany.com)
6.3. WEIGHTS
Machine net 120 kg
265 lb
Machine wrapped 170 kg
375 lb
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Technical data
6.4. AIRBORNE SOUND EMISSION

Measured values, with product, 300rpm
LpA emitted sound pressure level 72 dB(A)
6.5. DIMENSIONS
6.6. DIMENSIONS CRATE

WxHxD 880x970x720 mm
35x38x29 inch
6.7. ELECTRIC VALUES EU

3-phase mains connection
Voltage 380 .. 420 VAC
Control voltage 24 VDC
Frequency 48 .. 52 Hz
Max. power consumption 1300 W
6.8. ELECTRIC VALUES US

3-phase mains connection / solidly grounded
6.9. ELECTRIC VALUES JAPAN

3-phase mains connection / corner grounded delta
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Technical data

6.10. IP PROTECTION
Ingress protection IP32
6.11. ROLLER TEMPERATURE

CONTROL
Max. pressure at: pressureless cooling 1.0 .. 4.0 bar
14 .. 60 psi
Max. pressure at: pressure cooling 0.5 .. 2.0 bar
7 .. 30 psi
Maximum temperature change of supply temperature 30 °C / h
in tempering process per hour 54 °F / h
6.12. ROLLERS
Diameter 80 mm
Useful lengths 85 / 170 / mm
200*)
Temperature range 10 .. 55 °C
50 .. 130 °F
Rotational speed, roller 3 – operating mode gap 30 .. 700 rpm
Rotational speed, roller 3 – operating mode force 30 .. 300 rpm
Rotational speed, roller 3 – operating mode cleaning 30 .. 200 rpm
Rotational speed, roller 3 – operating mode cleaning 30 .. 70 rpm
USA complies with ANSI® B65/NAPIM 177.1-2017.
Roller force - working width 200mm*) 0 .. 22 N/mm

Roller force - working width 170mm 0 .. 26 N/mm
Roller force - working width 85mm 0 .. 26 N/mm
Gap widths gap operation 5 .. 180 Inc

Inc = increments
Gap width gap 2 / mixing operation ~0.7 mm
*) not for all types of rollers
26 27891EN-900-02 / Edition 02/2017

Unit description
7 UNIT DESCRIPTION
7.1. FUNCTIONAL PRINCIPLE

The machine disperses, de-agglomerates and homogenizes powdered
material to liquid or highly viscous suspensions. At the same time the
product is degassed.
The three rollers rotate reversely with various speeds in a speed ratio of
approx. 1:3:9.
Roller 3 (c) has the highest speed.
The product is supplied into gap 1 (a) where it is pre-dispersed.
Then the product is supplied to gap 2 (b), where the final dispersion takes
place.
The scraper knife (d) scrapes the product from roller 3 (c), and the product
flows off via the scraper socket (e).
The fineness of the final product can be influenced by various gap settings,
speed settings and the number of passes.
c
d
a b
Fig. 5: Functional principle
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Unit description
7.2. OVERVIEW
7.2.1. SECTION VIEW

e
b
d c
a g
h
f
Fig. 6: Section view
a Roller 1 e Safety device gap 1 (nip

b Roller 2 gap), divers
c Roller 3 f Splash tray with safety
d Plastic guides guard
prevent an overflow of the product at the g Scraper knives, various
roller ends. h Scraper socket
i Drive unit
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Unit description
7.3. OPERATING MODES
7.3.1. CLEANING
Fig. 7: Cleaning
 Scraper removed  Plastic guides removed

 Cleaning guard mounted  Rollers to max. gap value
7.3.2. MIXING
Fig. 8: Mixing
 Scraper swiveled off  Knife guard mounted

 Gap 1 in gap mode  Gap 2 <0.7mm
7.3.3. GAP-GAP
Fig. 9: Gap-Gap
 Scraper swiveled off  Gap 1 in gap mode

 Gap 2 in gap mode
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Unit description
7.3.4. GAP-FORCE
Fig, 10: Gap-Force
 Scraper swiveled off  Gap 1 in gap mode

 Gap 2 in force mode
NOTE
Destruction or damage to the rollers.
Machine must IN GENERAL be operated with product because else dry run
of the rollers causes damage or destruction of the rollers.
Force values set too high cause dry run and destruction of the rollers.
7.3.5. FORCE-FORCE
Fig. 11: Force-Force
 Scraper swiveled off  Gap 1 in force mode

 Gap 2 in force mode
NOTE
Destruction or damage to the rollers.
Machine must IN GENERAL be operated with product because else dry run
of the rollers causes damage or destruction of the rollers.
Force values set too high cause dry run and destruction of the rollers.
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Unit description
7.4. EMERGENCY STOP
Fig. 12: Emergency stop button
a Emergency stop button

 Drive motor stops  Gap values to maximum gap
width
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Unit description
7.5. SAFETY DEVICES

The safety devices prevent direct access to pull-in points as far as possible.
For operation of the machine, the following must always be mounted:
 Splash tray, safety sensor locked
 Cleaning guard or safety device nip gap (gap 1)
7.5.1. CLEANING
The cleaning guard prevents access to the nip gap. A separate safety sensor
detects that the cleaning guard is set into place. The motor torque is reduced.
The maximum roller speed is reduced.
e b
a
Fig. 13: Safety devices cleaning
a Cleaning guard
b Safety sensor, nip gap e Safety sensor, detects that
(gap 1) cleaning guard has been
c Splash tray with safety guard selected
d Safety sensor, splash tray
 Safety devices are  Separate safety sensor,

detected by safety detects that cleaning has
sensors been selected
 Drive motor stops  Gap values at maximum gap
value
32 27891EN-900-02 / Edition 02/2017

Unit description
7.5.2. ROUTINE OPERATIONS

The various safety devices prevent access to the nip gap as far as possible.
a b
Fig. 14: Safety devices routine operations
a Safety device nip gap, various c Splash tray with safety guard
b Safety sensor, nip gap (gap 1) d Safety sensor, splash tray
 Safety devices are detected

by safety sensors  Gap values at current gap
 Drive motor stops value
27891EN-900-02 / Edition 02/2017 33

Unit description
7.6. SAFETY MARKS
7.6.1. DANGER OF CRUSHING
Fig. 15: Warning note - danger of being pulled in by rotating rollers
Danger of crushing if pulled in by rollers
7.6.2. DANGER OF CUTS
Fig. 16: Warning note danger of cuts at the scraper knife
Danger of cuts
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Unit description
7.6.3. VOLTAGE
Fig. 17: Warning note voltage
Warning of voltage
7.6.4. INCREASED LEAKAGE CURRENT
Fig. 18: Warning note increased leakage current
Warning of increased leakage current;

fixed connection only!
27891EN-900-02 / Edition 02/2017 35

Unit description
7.6.5. TEMPERING FLUID
Fig. 19: Warning note tempering fluid
Use corrosion protection, minimum and

maximum supply temperature, maximum
media pressure
36 27891EN-900-02 / Edition 02/2017

Unit description
7.7. CONTROL ELEMENTS
7.7.1. FRONT SIDE
d k
a
b
c
o e
f
m
g
h
i
j
n
l
p
Fig. 20: Unit front side
a Roller 1 j Key switch „Release Reverse“

b Roller 2 k Emergency stop button,
c Roller 3 locking
d Safety device nip gap, various l Scraper socket, with scraper
e Operating unit knife, various
f Start button m Antenna stop switch,
g Stop button 2 pieces (Option)
h Receipt safety button n Scraper lever, to swivel off the
i Start button reversing mode, scraper socket
to reverse the rollers in case o Locking lever, to lock in
of overload by a product with swiveled off position
excessive viscosity p Setting dial for scraper force,
with scale
27891EN-900-02 / Edition 02/2017 37

Unit description
7.7.2. BACKSIDE
d
e c
i
b
f
m
l g
k o
h
Fig. 21: Unit backside
a Roller 1 k Connection for roller

b Roller 2 temperature control (return
c Roller 3 flow)
d Safety device nip gap, various l Locking cock inlet flow
e Operating unit m Level indication return flow
f Main switch ON/OFF, lockable (only with pressure-free
g Fuses cooling)
h Power cable input n Antenna stop switch,
i Emergency stop button, 2 pieces
locking o External interfaces (optional)
j Connection for roller
temperature control (inlet flow)
38 27891EN-900-02 / Edition 02/2017

Unit description
7.8. ROLLER TEMPERATURE CONTROL

The roller temperature control enables cooling or heating of the rollers. 2
different temperature control systems are available.
 Pressureless cooling
 Pressure cooling
For the temperature control of the three roller mill 80E PLUS,
EXAKT recommends using the cooling circulator bath thermostat
by HUBER, model MPC-K6. The unit can be procured via EXAKT
and is then delivered with tube connections matching the three
roller mill and with optimum control configuration.
NOTE
Danger of destruction of device components
It is mandatory to add Glysantin® G48® as corrosion protection to the
water. Operation with water without corrosion protection is not permitted.
Three roller mills with pressure cooling (closed circulation loop) must never
be run dry. Even if no temperature control of the rollers is required for the
application, tempering fluid must circulate through the rollers. This is required
to prevent damage to the rotary units or the rollers.
27891EN-900-02 / Edition 02/2017 39

Unit description
7.8.1. PRESSURELESS COOLING
NOTE
› Check coolant filling level during operation.
› If the filling level is steadily increasing in the green area or latest if it is too
high as indicated by the red area, there is a risk that coolant will overflow
within the machine.
Check coolant flow in the return flow for obstacles (kinks, cloggings, steady
gradient), reduce inlet flow if necessary
Fig. 22: Pressureless cooling, flowthrough direction
a Locking cock c Level indication return flow

b Temperature sensor (1x) trough
40 27891EN-900-02 / Edition 02/2017

Unit description
MAX
b
Fig. 23: Pressureless cooling, level indication return flow tank
a Locking cock b Level indication return flow

trough
27891EN-900-02 / Edition 02/2017 41

Unit description
7.8.2. PRESSURE COOLING
NOTE
Danger of destroying the seals in the rotary units (b).
› With pressure cooling, always ensure coolant flow during operation.
Fig. 24: Pressureless cooling, flow-through direction standard
a Locking cock c Temperature sensor (3x)

b Rotary unit (3x)
 3 temperature sensors for  Flow-through direction can

inlet flow temperature be reversed (optional)
 1 temperature sensor for

ambient temperature
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Unit description
7.9. SCRAPER SYSTEM

The scraper system consists of the scraper socket with exchangeable scraper
knife (various materials) that is swiveled to roller 3 to scrape off the product.
a
c
Fig. 25: Scraper socket with exchangeable scraper knife
a Scraper knife c Adaptor

b Scraper socket
7.10. LOAD TRAVERSE

The load traverse (a) serves for lifting for transport and for securing the machine
in the packaging. The clevis (b) receive the lifting gear.
Fig. 26: Load traverse, mounted to the machine
a Load traverse b Clevis
27891EN-900-02 / Edition 02/2017 43

Unit description
7.11. SCOPE OF DELIVERY
Symbol Meaning
Base unit
(roller material: either
- hard chrome plated steel
- tungsten carbide coated steel
- aluminum oxide
- silicon carbide
Load traverse (installed for delivery)

(To lift the machine and to secure it in the
transport box).
Keep lifting gear after installation!
Socket head screws M8x20
(are required after removing the load traverse,
see chapter
9.2
Dismounting the load traverse).
Operating unit with holder
Plastic guides (at customer's option)
Cleaning guard
Safety device nip gap, various - at customer's

option, but at least one
44 Edition 09/2016
Unit description
Symbol Meaning
Splash tray
Scraper socket
(with exchangeable scraper knife)
Knife guard (to be placed onto scraper socket

during handling, mounting, mixing operation)
Scraper bolt 1mm for scraper angle 110 °

(by default mounted in scraper socket)
By default mounted in scraper
socket
Allen screwdriver 4 mm
(for mounting the scraper knife and plastic
guides working width 200 mm)
Edition 09/2016 45
Unit description
Symbol Meaning
(for all safety devices)
Petroleum jelly 100 ml
Spatula
Operating instructions
Sheet with safety instructions
46 Edition 09/2016
Unit description
7.12. EQUIPMENT VARIANTS
Equipment variants Description

Pressureless cooling of the rollers (can be
Cooling / temperature operated without coolant flow)
control of the rollers Pressure cooling of the rollers via rotary units in
every individual roller (always requires coolant
flow)
Steel, hard chrome plated
Steel, tungsten carbide coated
Roller materials
Aluminum oxide
Silicon carbide
Safety Additional antenna stop buttons (2x)
External interfaces for EXAKT bus and
optionally:
Interfaces Emergency stop button
or
Start-stop button
Version with heavy duty connector (HARTING)
Electrical connection
as "pluggable" fixed connection
Edition 09/2016 47
Unit description
7.13. SAFETY DEVICES NIP GAP AND OPTIONAL

ACCESSORIES
The following safety devices and options are available for the EXAKT 80E
Plus.
The information in "mm" refer to the working width.
The machine is always delivered with at least one safety device:
7.13.1.SAFETY DEVICES
Safety devices Description
Nip Cover
Hopper 200 mm with plastic guides
Pull-in protection 200 mm
Safety bridge 200 mm, only for products that

are hard to process!
Hopper 170 mm
48 Edition 09/2016
Unit description
Safety devices Description
Safety bridge 170 mm, only for products that

are hard to process!
Safety bridge 85 mm, only for products that are

hard to process!
7.13.2.OPTIONAL ACCESSORIES
Optional accessories Description
Plastic guides working width 200 mm
Splash guard side plates, set (removable, for

easy cleaning)
Splash guard, set (for 200 mm working width)
Spring set guide shaft (for hopper 170 mm)
Edition 09/2016 49
Unit description
Optional accessories Description
Guide shaft 170 mm, blue and black
Guide shaft 85 mm, blue and black
Scraper knife, various versions
Scraper constriction 60 mm
Roller cover with adapter for aspiration
Solvent dispenser for guide lubrication, set

(in some cases it is required to lubricate the
plastic guides additionally against running dry)
Protective cover
Plastic spatula
50 Edition 09/2016
Transport
8 TRANSPORT
8.1. PACKAGING SYMBOLS
Transport the machine only with suitable lifting gear. Observe

the total weight of the machine with packaging (see chapter 6
Technical data).
Transport the machine carefully!
NOTE
Danger of transport damage!
Upon delivery, the packaging is equipped with a position sensor (TILT
sensor). Immediately at delivery by the carrier, check if the sensor is intact.
If not, notify the carrier immediately and let the driver confirm this.
The transfer of risk from manufacturer to final customer takes place with
leaving the factory premises of EXAKT / Germany.
NOTE
Danger of damaging machine components.
› Do not lift or put down the machine jerkily!

› Pay attention to the center of gravity!
› Do not tilt the packaging! Pay attention to the UP symbols! TILT sensor!
› Do not put down the machine outside of roofed buildings (protect from
humidity).
Symbol Meaning
Up
Keep dry
Center of gravity
Edition 09/2016 51
Transport
Symbol Meaning
Fragile
Positions for
lifting gear
Positions for
forklift forks
The TILT sensor indicates whether the machine has

been tilted during transport.
8.2. INTERMEDIATE STORAGE

› Leave the machine in the packaging until it is installed
› Protect the machine from outer influence (humidity, etc.)
› Avoid temperature fluctuation, danger of corrosion due to condensation
› Relative humidity max. 65 %
› Antifreeze during transport and storage: Drain cooling lines completely.
8.3. UNCRATING
Cordless screwdriver, crosstip-bit,
Additional person to help.
NOTE
Danger of transport damage!
Upon delivery, the packaging is equipped with a position sensor (TILT
sensor). Immediately at delivery by the carrier, check if the sensor is intact.
If not, notify the carrier immediately and let the driver confirm this.
The transfer of risk from manufacturer to final customer takes place with
leaving the factory premises of EXAKT / Germany.
52 Edition 09/2016
Transport
Abb. 27: Machine crate Abb. 28: Remove crate top cover
1. Unscrew the crate top cover (a), 10 screws.
Abb. 29: Take out machine accessories Abb. 30: Remove intermediate cover
2. Take out the machine accessoires and store it at a safe place..

3. Unscrew the intermediate cover (b), 8 screws.
4. Remove the intermediate cover.
Edition 09/2016 53
Transport
~12 kg
~26,5 lb
Abb. 31: Remove the screws and lift the crate outside frame
5. Remove the 10 screws for the crate outside frame (c).

6. Lift the crate outside frame securely to the top (2 persons).
NOTE
Danger of component damage.
When lifting the crate outside frame (c), do not come in touch with the
machine housing.
7. Remove the padding on the machine.
Abb. 32: Lift machine from crate base Abb. 33: Crate pick-up plate for machine frame
8. Attach the suitable lifting rope at the load traverse and lift the machine with
the suitable lifting gear from the crate base (see chapter 8.4 Instructions for
lifting).
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Transport
8.4. INSTRUCTIONS FOR LIFTING
WARNING
Suspended load
Danger to life and limb
› Only use functional lifting gear

› Make sure that no persons are within the danger zone
› Do not step under or stand under suspended load.
› Wear protective footwear, protective gloves and head protection
NOTE
Danger of damaging the rollers:
› Do not drop heavy objects onto the rollers

› Protect rollers from damage by sufficient padding.
NOTE
Danger of damaging machine components.
› Do not lift or put down the machine jerkily!

› Pay attention to the center of gravity!
› Do not tilt the packaging! Pay attention to the UP symbols! TILT sensor!
› Do not put down the machine outside of roofed buildings (protect from
humidity).
› Lifting gear must be suitable for the load to be lifted (see chapter 6 Technical
data).
› Lifting aids must be mounted correctly.
› Lifting aids must have a lifting capacity that is at least three times as high as
the load to be lifted (see chapter 6 Technical data).
› Lifting aids must be in perfect condition.
› Lift machine only with the original load traverse provided by EXAKT.
› Take up the machine in the 2 heavy load clevis (a).
27891EN-900-02 / Edition 02/2017 55

Transport
120 kg
265 lb
Fig. 34: Lifting the machine
› The angle of the lifting rope must not exceed 60°!

Secure the lifting rope against slipping out of place (e.g. loop around the fork of
the fork lifter, see b)
› Lift the machine as horizontal and jerk-free as possible.
56 27891EN-900-02 / Edition 02/2017

Transport
8.4.1. MOVING THE MACHINE BY HAND

The machine can be moved by hand. For this purpose, recessed grips are
provided on the left and the right below the machine.
120 kg
265 lb
Fig. 35: Lifting the machine by hand
› Lift the machines only by the recessed grips
› NEVER lift the machine via the attachment parts such as operating unit,
holder arm for operating unit, cooling connections, etc.!
CAUTION
Danger of crushing the hands
If the machine is moved by 2 persons, make sure to lift up
simultaneously. If the machine is only lifted on one side, the
other person is at risk of crushing.
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Installation
9 INSTALLATION
9.1. SETUP SITE
Fig. 36: Setup site and dimensions
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Installation
› Select a location with sufficient room at all sides for operation and cleaning
› Distance to the walls at least 300mm to the left and right of the machine.
Distance to the walls at the backside at least 30mm
› Set up on flat and slip-free surface
› Lab table with a bearing capacity of at least 150kg
› The setup site must meet the specifications given in the safety data sheets of
the substances to be processed, especially when working with highly volatile
solvents.
› Lift machine only with the original load handling equipment provided by
EXAKT.
› After installation, dismount load handling equipment and store safely.
WARNING
Suspended load
Danger to life and limb
Danger of crushing
Impacts
Tripping
› Only use functional lifting gear.

› Make sure that no persons are within the danger zone.
› Do not step under or stand under suspended load.
› Wear protective footwear, protective gloves and head protection.
NOTE
› Do not drop heavy objects onto the rollers.

› Protect rollers from damage by sufficient padding.
27891EN-900-02 / Edition 02/2017 59

Installation
9.2. DISMOUNTING THE LOAD TRAVERSE

a
b
Fig. 37: Dismounting the load traverse
› After setup, dismount the load traverse.

1. Undo 2 Allen screws (a) and remove load traverse carefully. Do not damage
the rollers in this step!
2. Mount provided 2 Allen screws M8x20 (b)
› Store load traverse with screws (a) for later transport!
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Installation
9.3. MOUNTING AND ALIGNING THE OPERATING UNIT

c
a
Fig. 38: Mounting the operating unit Fig. 39: Connecting the plug connections
1. Mount the operating unit (a) in the holder arm (b) with the screw (c) and the
washer (d).
2. [1] Plug in network cable (black)
3. [2] Plug green cable onto the plug connector and secure with union nut.
Fig. 40: Aligning the operating unit horizontally Fig. 41: Aligning the operating unit vertically
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Installation
9.4. CONNECTING THE ELECTRIC SUPPLY
WARNING
Danger of electric shock!
Incorrect mounting of the connecting cable can cause severe injury
due to electric shock.
› Only allow a trained electrician to connect the machine.
The electrical installation of the unit must be done by specialized personnel who
are qualified according to the local or legal requirements and regulations.
When connecting machines without frequency converter (progressive speed
control), pay attention to the correct rotary field. These machines require a
clockwise rotary field. Roller 3 (delivery roller) must rotate towards the scraper.
Should that be not the case, check if the rotary field is correct and correct, if
necessary.
Before connecting the unit, make sure that the local system is in perfect
condition according to the legal requirements of the respective country.
9.4.1. NETWORK CONFIGURATION
Article Voltage Description / Sign on type plate

number
27100 380-420VAC Solidly grounded Wye
50Hz 3 / N / PE (5 lines)
EU, (…) TN-S / TN-C-S / TT
27101 200-240VAC 50- Solidly grounded Wye

60Hz 3 / PEN (4 lines)
USA, (CN)
27105 200-240VAC 50- Corner grounded Delta

60Hz (3 lines)
Japan, (USA)
62 27891EN-900-02 / Edition 02/2017

Installation
9.4.2. CONNECT VARIANT 1: FIXED CONNECTION

We recommend to select a fixed connection for the unit. This connection variant
does not require a ground fault circuit interrupter and ensure proper operation.
Label (color)
Mains supply 400 V 200 V (USA, Jap.)
N (MP) N (black)
L1 L1 (black)
L2 L2 (black)
L3 L3 (black)
PE none (green/yellow)
PE rail
none (16 mm² green/yellow)

Eye 8 mm
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Installation
9.4.3. CONNECTION VARIANT 2: FIXED CONNECTION

WITH CODED HEAVY DUTY CONNECTOR
Upon request, EXAKT will deliver the machine with heavy duty connector
HARTING type: Han 6x. This connection variant does not require a ground fault
circuit interrupter and ensure proper operation.
A corresponding wall-mounting socket HARTING type: Han 6x with plug insert
6-poles will be provided which shall be connected as follows:
Label (color)
N (MP) PIN 4
L1 PIN 1 PIN 4
L2 PIN 2 PIN 5
L3 PIN 3 PIN 6
PE PE
PE rail

Eye 8 mm
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Installation
Fig. 42: Connection variant 2: fixed connection with coded heavy duty connector
Coding HARTING socket / connector
Coding pin at pin 1 (socket, top view)
400V
200V (USA, Jap)
Coding pin at pin 4 (socket, top view)
27891EN-900-02 / Edition 02/2017 65

Installation
9.4.4. CONNECTION VARIANT 3: CONNECTION VIA

THREE-POLES STANDARD PLUG (MIN. 15A)
If the unit is equipped with a three-pole standard connector (in Germany e.g.
CEE plug 16A acc. to DIN EN 60309), an RCCB type B 30mA acc. to DIN EN
61008 must be installed in the system to be connected.
All-current sensitive RCCBs (alternating current, pulsating direct current and
direct current) of type B react to all types of residual current. A typical
application is the protection of circuits containing frequency converters. In all
three roller mills with speed control (80S, 80E and all 120E models), frequency
converters are used to adjust the speed.
Note: When switching off the unit, the intermediate circuit of the frequency
converter discharges and the RCCB can potentially be triggered by mistake!
Therefore we recommend to install a separate circuit with RCCB for this
machine in that connection variant.
WARNING
When using RCCBs of type A, which are not designed for all
types of residual currents, erroneous triggering can occur, or the
DC voltage generated by the frequency converter causes a bias
current making the RCCB lose its function!
66 27891EN-900-02 / Edition 02/2017

Installation
Label (color)
N (MP) N (black)
L1 L1 (black)
L2 L2 (black)
L3 L3 (black)
PE none (green/yellow)
PE rail

Eye 8 mm
27891EN-900-02 / Edition 02/2017 67

Installation
9.5. CONNECTING THE ROLLER TEMPERATURE

CONTROL
Screwdriver, knife
Fig. 43: Temperature control connections
a Inlet flow nozzle OD 10 mm c Locking cock inlet flow

b Return flow nozzle OD 13 mm
1. Connect hose (ID10 mm) to the inlet flow nozzle (a) and secure with a hose
clamp.
2. Connect return flow hose (ID 13 mm) to the discharge nozzle (b) and secure
with a hose clamp.
3. Make sure that the hose runs with a steady gradient without windings directly
to the temperature control unit to prevent overflow of the tempering fluid due
to obstructed return flow.
4. Open locking cock half way (in Fig. shown completely open).
9.5.1. TEMPERATURE CONTROL UNIT

For the temperature control of the three roller mill 80E PLUS,
EXAKT recommends using the cooling circulator bath
thermostat by HUBER, model MPC-K6. The unit can be
procured via EXAKT and is then delivered with tube connections
matching the three roller mill and with optimum control
configuration.
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Installation
NOTE
Danger of roller damage: Using a tempering fluid without corrosion protection
results in corrosion inside the rollers.
Observe the coolant specification (see chapter 6 Technical data).
NOTE
5. Inlet flow temperature of the rollers min. 10 °C (50 °F) to max. 55 °C
(130 °F).
6. Maximum temperature change of supply temperature in temperature
control process: 30 °C/h (54 °F/h) !
› Adjust the settings at the temperature control unit accordingly.

› If necessary, program the maximum temperature limits to be set at the
temperature control unit (see operating instructions of the temperature
control unit).
› Fill the temperature control unit with water and corrosion protection agent.
› At the temperature control unit, set a bath temperature of approx. 20 °C.
› Switch on the pump of the temperature control unit and check proper coolant
flow after some minutes.
› Switch off the pump.
9.5.2. WITH PRESSURELESS COOLING
NOTE
› Check coolant filling level during operation.
› If the filling level is steadily increasing in the green area or latest if it is too
high as indicated by the red area, there is a risk that coolant will overflow
within the machine.
› Check coolant flow in the return flow for obstacles (kinks, cloggings, steady
gradient), reduce inlet flow if necessary.
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Installation
9.5.3. WITH PRESSURE COOLING
NOTE
Danger of destroying the seals in the rotary units
› With pressure cooling, always ensure coolant flow during operation.
9.6. CHECKLIST INSTALLATION
No. Description
1 Load traverse dismounted. M8x20 screws are mounted.
2 Electrical connection completed.
3 Temperature control unit connected. All connections are tight.
4 There are no foreign objects in or on the machine.
70 27891EN-900-02 / Edition 02/2017

Setup
10 SETUP
In this section, the following mounting and installation tasks are
described for:
 Cleaning the machine housing
 Scraper knife and scraper
 Knife guard
 Splash tray
 Cleaning guard
 Plastic guide for working widths 85, 170, 200 mm
 Nip cover for working widths 85, 170, 200 mm
 Pull-in protection for working widths 85, 170, 200 mm
 Safety bridge for working widths 85, 170, 200 mm
 Hopper for working width 170 mm
 Hopper for working width 200 mm
 Splash guards
 Solvent dispenser
10.1. CLEANING THE MACHINE HOUSING
CAUTION
Solvent and product residue
Skin irritation and breathing difficulties are possible.

› Observe the safety data sheets of the substances to be
processed.
› Observe the disposal instructions by the respective
manufacturers.
1. Switch off the machine via the main switch.

2. Do not clean housing parts with aggressive solvents.
3. Clean electric cables and parts made of rubber or EPDM with a moist cloth.
› Ensure proper disposal of the waste.
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Setup
10.2. SCRAPER KNIFE TYPES

The different scraper knives can be combined with the various roller types as
follows:
Roller type
Scraper knife
Tungsten
Hard chrome Al2O3 SIC
carbide
Art.-No. Des.
Metal, ZrO2
27320 (hybrid knife)
218x0.35x30
Solidknife ZrO2
27325
218x0.63x25
nickel-plated
27330 *) *) *)
218x0.35x30
hard chrome
27350 plated
218x0.35x30
PVC, red
27360
218x1x30
Epoxy, yellow
27370
218x1x30
Ceramic, ZrO2
27380
218x1,7x30
Ceramic, Al2O3
27390
218x1,7x30
*) not recommended, increased wear
NOTE
Avoid danger of premature wear due to incorrect scraper knife-roller type
combination
› Pay attention to the combination!
27330 is marked with a 45°-chamfer (as distinct from 27350).
72 27891EN-900-02 / Edition 02/2017

Setup
10.3. MOUNTING THE SCRAPER KNIFE
CAUTION
› During assembly and handling, ALWAYS work with plastic knife
NOTE
Ceramic scraper knife Danger of breakage
› In particular with ceramic scraper knives, pay attention to careful handling.
b c e a
Fig. 44: Mounting the scraper knife
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Setup
1. Before assembly, clean all parts.

2. Mount scraper bar (e) with 3 screws (c) to the scraper socket (a).
3. Loosen the clamping screws (b).
4. Insert scraper knife (f) (with plastic knife guard). Make sure that the sharp
edge points forwards and the sharpened side of the knife edge points up, i.e.
is visible. (see arrow in detail A).
5. Push scraper knife to the stop (g) of the scraper bar (on the right, viewed
from the top).
6. Mount adaptor (d). Make sure that the groove of the adaptor sits in the stop
of the scraper bar.
7. Tighten the clamping screws (b) ! hand-tight ! as required.
8. Before operation, remove the plastic knife guard and put on the knife guard
for the scraper socket.
74 27891EN-900-02 / Edition 02/2017

Setup
10.3.1.COMBINATION SCRAPER KNIFE – SCRAPER BAR -

ADAPTOR
The different scraper knives (f) need different scraper bars (e) and adaptors (d).
Scraper bar (e)
Scraper knife (f) Adaptor (d)

Silver Black
27394 27393
Art.-No. Des.
Metal, ZrO2
2 mm
27320 (hybrid knife)
27392
218x0.35x30
Solidknife ZrO2 2 mm
27325
218x0.63x25 27392
nickel-plated 2 mm
27330
218x0.35x30 27392
hard chrome
2 mm
27350 plated
27392
218x0.35x30
PVC, red 2 mm
27360
218x1x30 27392
Epoxy, yellow 2 mm
27370
218x1x30 27392
Ceramic, ZrO2 1mm
27380
218x1,7x30 27391
Ceramic, Al2O3 1mm
27390
218x1,7x30 27391
27330 is marked with a 45°-chamfer (as distinct from 27350).
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Setup
10.4. PUTTING ON THE KNIFE GUARD

The knife guard for the scraper socket protects from cuts during:
› Removing the scraper socket and putting it into place
› Storing the scraper socket
› Mixing operation while the scraper is swiveled off
For rapid access, the knife guard can be fastened with magnets on the machine
while it is not in use.
CAUTION
Fig. 45: Mounting knife guard for scraper socket Fig. 46: Knife guard in „park position
1. Push knife guard over the scraper socket slightly bending open the clamping
holder. While doing so, position the knife guard at the front edge of the
scraper socket and push on completely.
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Setup
10.5. ADJUSTING THE SCRAPER CONTACT PRESSURE

The contact pressure of the scraper system is generated by an adjustable
tension spring. The tension spring is adjusted via the adjustment wheel (a). The
hand (b) displays the value on a scale.
Low scale value = low contact pressure, high scale value = high contact
pressure
Fig. 47: Increasing the scraper contact pressure Fig. 48: Reducing the scraper contact pressure
a Setting dial for scraper force

b Scale
› Increase scraper contact pressure by turning the wheel to the right.

› Reduce scraper contact pressure by turning the wheel to the left.
1. Set scraper contact pressure to the minimum value at which the product is
removed neatly. In general, the scale value should be 1..2.
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Setup
If the contact pressure is too high or too low, product removal

might deteriorate.
Contact pressure too high increases wear of the scraper knife.
At first installation, the contact pressure is set to minimum
pressure.
For the characteristics if the contact pressure is too low, refer to
chapter 15 Troubleshooting.
We recommend not to increase the contact pressure higher than
the scale value 3; else check the scraper knife for proper
function should it be necessary nonetheless.
10.6. MOUNTING THE SCRAPER SOCKET

a c
Fig. 49: Swiveling off the scraper base
a Scraper base, movable with 2 Levier de raclage,

b Scraper pour
lever, to faire pivoter
swivel off thel'unité de
commande de la prise de racloir
pin receptacles (borings). For scraper socket operating unit.
autonomous alignment of the c Locking lever, to lock
Levier de verrouillage pour in swiveled
verrouiller la position pivotée
scraper knife in parallel to the off position
roller.
1. Set the scraper force to minimum force (scale value 1).

2. Swivel off scraper lever (b) until locking lever (c) snaps in.
3. Check pin receptacles of the scraper base for impurities, clean if necessary.
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Setup
Fig. 50: Set scraper onto scraper base
4. Check location hole at the scraper for impurities.

5. Set scraper socket (with scraper knife and knife guard for scraper socket)
onto the two pin receptacles. Make sure that the scraper socket sits
completely and is not "tilted".
a c
Fig. 51: Removing knife guard Fig. 52: Swiveling in scraper
6. Remove the knife guard (a).

7. Swivel off the scraper lever (b) and unlock locking lever (c) (press down).
8. Carefully swivel the scraper socket to the roller.
NOTE
Ceramic scraper knife Danger of breakage
› In particular with ceramic scraper knives, pay attention to careful handling.
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Setup
10.7. ALIGNING THE SCRAPER SOCKET IN PARALLEL TO

THE ROLLER
Fig. 53: Aligning the scraper socket in parallel
1. Swivel the scraper socket (b) to the roller with the knife inserted.
2. Undo the fixing screw (a) slightly with Allen screwdriver so that the scraper
base with scraper socket in place can move freely.
 The knife aligns itself in parallel to the roller.
3. Tighten the fixing screw with the Allen screwdriver hand-tight.
The scraper base only needs to be aligned in case of knife

change. The fixing screw can in general remain fixed.
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Setup
10.8. SETUP OF THE SCRAPER ANGLE

The scraper angle can be set in 3 different positions. Depending

on the product, it might be required to adjust the angle for
removing the product.
For this purpose, scraper bolts with different lengths are
screwed to the scraper socket to change the tangent angle of
the scraper knife to the roller.
The table below contains the corresponding tangent angle for
the length of the scraper bolts.
Scraper bolts Tangent angle scraper knife - roller

1 mm approx. 110°
4 mm approx. 115°
8 mm approx. 120°
Fig. 54: Mounting the scraper bolts for different scraper angles (tangent angles)
1. Screw off both scraper bolts with an Allen screwdriver.

2. Clean both receptacle holes.
3. Mount the scraper bolts of the desired length and tighten with Allen
screwdriver.
The different scraper angle positions might render it necessary

to adjust the scraper contact pressure.
The higher the tangent angle, the higher the scraper contact
pressure needs to be, and vice versa.
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Setup
10.9. MOUNTING THE SPLASH TRAY

Fig. 55: Mounting the splash tray
1. Swivel off scraper lever (a) until locking lever (b) snaps in.
2. Push in splash tray (c) from the front. Make sure that the splash tray does
not touch the rollers.
3. Swivel in latch (d).
4. Secure latch with Allen screwdriver.
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Setup
10.10. MOUNTING THE CLEANING GUARD

When cleaning the roller surfaces, the cleaning guard prevents body parts or
foreign objects (e.g. cleaning towel) being pulled in and thus prevents the
components being destroyed.
WARNING
Danger of being pulled in by the rollers during cleaning
› When cleaning, always mount the cleaning guard.
› On no account clean with other safety devices.
NOTE
Destruction of components due to being pulled into the roller gap
› When cleaning, always mount the cleaning guard. On no account clean with
other safety devices.
b
a c
Fig. 56: Mounting the cleaning guard
1. Place cleaning guard (a) from above onto the centering mounts (d).
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Setup
NOTE
The centering mounts (d) fix all safety devices for the nip gap in the correct
position.
› Make sure that the safety device sit well on the centering mounts before
securing the latches.
2. Swivel in left latch (b) and right latch (c) successively.

3. Secure both latches successively with Allen screwdriver.
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Setup
10.11. INSERTING PLASTIC GUIDES FOR WORKING

WIDTH
85 MM AND 170 MM
WARNING
Danger of being pulled in by the rollers in case of incorrect length
of the guide shafts:
› Always select the same length for both guide shafts matching the
selected working width. Insert the corresponding safety devices
only according to the selected working width.
NOTE
Roller destruction due to incorrect input of the working width (E-models)
› In general, program the working width of the used safety device via the
operating unit. Else the line force values [N/mm] will not correspond.
Danger of roller destruction in force mode.
The plastic guides for the working widths 85 and 170 mm consist each of the
following units:
 Plastic guide (a)
 Guide shaft 85 or 170, blue (b)
 Guide shaft 85 or 170, black (c)
 Springs (d) for work with hopper
 Depending on the working width, the guide shafts are screwed into the
plastic guide.
 The color coding helps in inserting the plastic guide into the machine on
the correct side.
 Also at the machine are a blue and a black screw on the left and right
central mount, respectively, that can be used as side orientation.
 Left machine side: blue
 Right machine side: black
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Setup
c
a
a d
Fig. 57: Plastic guide WW 85mm and 170mm: Assembling parts
1. Select guide shafts for the desired working width

2. Screw guide shaft (b, c) into plastic guide (a) hand-tight.
3. For working with hopper, additionally push the springs (d) onto the guide
shafts 170. The springs seal the guides against the hopper.
Fig. 58: Inserting plastic guides for working width 85 mm and 170 mm
(Shown here: working width 170 mm)
4. Insert guide shaft (a) into the hole of the guide tube (b).
5. Lift guide shaft slightly with index finger.
6. Push in plastic guide up to the stop.
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Setup
10.12. MOUNTING PLASTIC GUIDES FOR WORKING

WIDTH 200 MM
NOTE
Leaks in product flow at working width 200:

The plastic guides have a blue (left plastic guide) or black screw
connection, respectively. The plastic guides wear differently. In
order to avoid leaks, the plastic guides must always be used on the
same side.
› Observe the color coding blue (left) and black (right).
› Replace worn plastic guides.
The plastic guides for the working width 200 mm consist each of the following
units:
 Plastic guide shoulder roller (a), wear parts
 Top for shoulder guide (b) / top for shoulder guide, hopper (b.1)
 The tops (b) are each screwed onto the plastic guides (a) (wear part) (c, d)
and (c, e). The blue screw (d) or the black screw (e) help to insert the
plastic guides on the correct side into the machine
 Also at the machine are a blue and a black screw on the left and right
central mount, respectively, that can be used as side orientation.
 Left machine side: blue
 Right machine side: black
 Clamping cone for shoulder guide (f).
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Setup
c
e
d
b
f
a
a
c
b
f
b.1
c
d
Fig. 59: Plastic guide working width 200mm: assembling parts
1. Screw together plastic guide - shoulder guide (a) with top for shoulder guide
(b) / top shoulder guide, hopper (b.1). Pay attention to the color code with the
blue or black screw, respectively. The front edges of the plastic guide and the
tops must be flush.
f h
Fig. 60: Plastic guide working width 200mm: assembling parts
2. Insert clamping cone for shoulder guide (f) into the drilled hole of the guide
tube (g).
3. Lift clamping cone slightly with index finger.
4. Push in clamping cone up to the stop.
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Setup
5. Use an Allen screwdriver to turn the clamping cone (h) all the way up.
Fig. 61: Inserting plastic guides for working width 200 mm (shoulder roller)
(here: with top for shoulder guide)
Fig. 62: Inserting plastic guides for working width 200 mm (shoulder roller)
(here: with top for shoulder guide, hopper)
6. Insert plastic guide (a) at an angle from above under the clamping cone.
Make sure that the sharp edges of the rollers do not damage the sealing
surfaces (b).
7. Tighten the clamping cone with the Allen screwdriver HAND-TIGHT.
NOTE
Premature wear:
› Only tighten the clamping cone as much as necessary so that the plastic
guide seals. The stronger it is tightened, the faster the sealing surface of the
plastic guide will wear.
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Setup
10.13. MOUNTING THE SAFETY DEVICE NIP GAP,

WORKING WIDTHS 85 MM, 170 MM, 200 MM
NOTE
In principle, all safety devices for the nip gap are mounted in the
same way. There are only differences in mounting the hopper.
c d
Fig. 63: Mounting safety device for nip gap
1. Mount plastic guides matching the working width.

2. Set the safety device (a) for the corresponding working width from above
onto the centering mounts (b). Make sure that the safety device sits correctly
on the centering mount.
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Setup
3. Swivel in latch (c) and latch (d) successively.

4. Secure both latches successively with Allen screwdriver.
10.14. MOUNTING HOPPER FOR WORKING WIDTH

170 MM
NOTE
The hopper base (a) 170 mm is mounted the same way as other
safety devices for the nip gap. In addition, the safety guard (b) is
mounted to the hopper. The safety guard can be dismounted for
easier cleaning.
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Setup
a b
Fig. 64: Mounting hopper for working width 170 mm
1. Mount plastic guide 170 mm with springs (see chapter 10.11 Inserting plastic
guides for working width
85 mm and 170 mm).
2. Mount hopper base (a). In doing so, push in the plastic guides completely
against the spring pressure. The plastic guides will then later fit closely to the
outer wall of the hopper base.
3. Screw tight hopper base with the Allen screwdriver.
4. Insert safety guard (b) from above.
5. Screw tight safety guard with the Allen screwdriver.
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Setup
10.15. MOUNTING HOPPER FOR WORKING WIDTH

200 MM
Allen screwdriver 4 mm, 6 mm
NOTE
Fig. 65: Mounting hopper for working width 200 mm
1. Mount plastic guides with „top for shoulder guide, hopper“ (see chapter 10.12
Mounting plastic guides for working width 200 mm).
2. Screw out both securing bolts (a) up to the stop.
3. Carefully insert both hopper plates (b) into the guide slots of the plastic
guides up to the lower stop.
4. Set protective grid onto the hopper plates.
5. Set hopper safety guard (c) into place.
6. Screw in both securing bolts (a) with the Allen screwdriver.
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Setup
10.16. MOUNTING SPLASH GUARDS FOR WORKING

WIDTH 200 MM
Whenever necessary, the two splash guards (a) prevent the

product being ejected from the first roller and darting through the
room.
Fig. 66: Mounting splash guard for working width 200mm
1. Undo blue or black screw, respectively, at the central unit.

2. Push in splash guards (a) and screw tight.
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Setup
10.17. MOUNTING SPLASH GUARDS FOR INNER

SIDE PANELING
The splash guards (a) for the inner side paneling facilitate
cleaning the side paneling as the plates can be removed for
cleaning.
Fig. 67: Mounting splash guard for inner paneling
› The plastic guides must have been removed.

› The splash tray (b) must be mounted.
2. Push in splash guards (a) from above.
3. Push with the lock cutout (c) over the screw and engage.
4. Tighten blue or black screw, respectively.
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Setup
10.18. MOUNTING THE SOLVENT DISPENSER FOR

GUIDE LUBRICATION
Open-ended spanner 22 mm
NOTE
Destruction of rollers with working widths 85 mm and 170 mm in force mode
(E-models):
Due to low gap widths and high line pressure, we recommend to operate the
machine with a solvent dispenser for guide lubrication in force mode in order
to enhance protection of the rollers against damage.
Fig. 68: Mounting splash guard for inner paneling
1. Mount plastic guides matching the working width.

3. Undo nut at dispenser (a) with open-end spanner 22 mm so that the
dispenser can move in its holder (b).
4. Push in holder (b) and align position.
5. Tighten hexagon socket screw.
6. Align the tube of the dispenser so that the dry run area is wetted.
7. Tighten nut size 22.
8. Close dispenser valve completely and fill dispenser.
9. Open the dispenser valve according to the required amount.
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Operating elements and operating unit
11 OPERATING ELEMENTS AND OPERATING UNIT
The following chapter describes the operation of the operating

unit. These operating instructions contain all basic menu items
for operating the machine. For the complete menu guide of the
operating unit, refer to the separately provided operating
instructions "Operating unit EXAKT E Plus".
11.1. MAIN SWITCH
The main switch (a) switches the power of the machine on or off.
It can be secured with a padlock against unauthorized startup.
Fig. 69: Main switch (position shown: OFF)
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11.2. OPERATING PANEL
The operating panel controls the basic functions of the machine

such as:
› Start and stop of the roller drive.
› Receipt safety of the safety devices.
› Reversing in case of overload or foreign objects being pulled in,
in order to move the product / foreign object in reverse direction
out of gap 1.
Fig. 70: Operating panel with operating buttons
a Start button, starts the drive

motor with the preselected d Start button reversing mode,
roller speed to reverse the rollers in case
b Stop button, stops the drive of overload by a product with
motor excessive viscosity
c Receipt safety button All e Key switch „Release Reverse“
safety devices must be The key can be pulled off in
mounted. The emergency the non-released position and
stop button must be unlocked. kept at a safe place.
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11.3. EMERGENCY STOP BUTTON
Fig. 71: Actuating the emergency stop button Fig. 72: Unlocking the emergency stop button
1. Actuate emergency stop button.

2. Rectify the fault.
3. Unlock the red button of the emergency stop button.
4. Actuate receipt safety button (confirm safety circuit).
 Machine is ready to start again.
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11.4. OPERATING UNIT
The operating unit takes over all functions to control the machine
during operation:
› Cleaning mode.
› Routine operations with setting of the operating parameters such
as rotational speed, gap or force mode.
› Programming program sequences such as mixing, programs with
up to 9 passes with different operating parameters.
d b
g j i h f
Fig. 73: Operating unit
a Control dial gap 1 with g Arrow left, e.g. to display other

pushbutton screens to the left
b Control dial gap 2 with h OK button, to confirm an
pushbutton action like entering a
c Control dial roller speed with password or in the main menu
pushbutton i Home button, back to main
d Display menu
e Control keys j USB interface, for data
(5 pieces) to select various transfer
functions
f Arrow right, e.g. to display
other screens to the right
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d e
b g
c h
Fig. 74: Layout of the user interface, three parts, shown: routine operations
a Upper display field g Enable for control dial with

b Center display field inner red arrow control dial
c Lower display field can additionally be pressed to
d Status messages safety select other modes
controller h Enable for control dial (e.g.
e Status messages software setting the speed)
f Information lines i Toolbar with assignment of
control keys (menu-
dependent)
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11.4.1.SAFETY MESSAGES ON THE DISPLAY
For operation of the machine, all safety devices must be

mounted correctly. This is monitored by the safety circuit, roller
start will else not be released. Incorrectly mounted safety
devices or unsafe conditions are indicated on the display.
Fig. 75: Safety message splash tray Fig. 76: Safety message upper safety guard (hopper, nip
cover, etc.)
Fig. 77: Safety message cleaning guard Fig. 78: Safety message emergency stop
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› Check that the respective safety device has been mounted correctly according
to these instructions.
› In case of EMERGENCY STOP: Rectify fault and unlock button
 After the fault has been rectified and/or mounting has done correctly, you
automatically jump to the selected menu.
Fig. 79: Safety message receipt safety
WARNING
Before every machine operation, make sure that safe operation is
ensured beyond the safety devices of the machine.
› Adhere to proper use of the machine.
› Use the personal protective equipment.
› Observe the warning and safety notes at the machine and the
products to be processed.
› Follow the company-internal and legal regulations.
› Actuate receipt safety button (lights blue) on the operating panel.

 The blue receipt safety button goes off.
 Starting the rollers with the start button is now possible.
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11.4.2.OVERLOAD MESSAGES ON THE DISPLAY
The roller drive automatically stops in case of overload to protect

the machine.
Such events are indicated by the following messages:
Fig. 80: Force exceeded - Line pressure too high Fig. 81: Drive overload
Fig. 82: Drive overheated
› Rectify the cause of the fault.

› Confirm that fault has been rectified with control key .
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11.5. PROGRAM STRUCTURE
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Operation
12 OPERATION
This section describes operation of the three roller mill:

› Switching on the machine.
› Cleaning the rollers.
› Adjust the machine.
› Defining the pre-settings (setup)
› Routine operations: Test run with petroleum jelly.
WARNING
fingers.
mode.
› In routine operation, always work with the limiting jaws inserted to
the correct working width (according to the selected safety
device).
› In routine operation, supply or remove product only with the
spatula.
› Only use one-part spatulas or riveted spatulas with long handle.
› ALWAYS keep the spatula as far away as possible from gap 1
(nip gap roller 1 and roller 2).
WARNING
Danger of scalding:
› Before handling temperature control media, let them cool down.
› Wear safety gloves and protective clothing.
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Operation
WARNING
Danger of eye injuries due to rotating rollers or when handling
product and cleaning agents
› In general, wear eye protection.
CAUTION
CAUTION
carefully.

processed.
manufacturers.
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Operation
12.1. SWITCHING ON THE MACHINE
1. Switch on the machine via the main switch.

 The machine starts and the operating unit boots with the following screen:
Machine operation
only by authorized
and trained staff !
Fig. 83: Start screen Fig. 84: Password entry
With the control key you can call up information on the

machine.
To enter the 4-digit password:

1. Set digits by turning the control dial 3.
2. Jump to the next digit by pressing the control dial.
3. Finish entering the password with the control key .
 You access the main menu.
The main menu displays operating hours, time to next service and remaining
payment period, if applicable.
From the main menu you call up the other sub-menu to operate the machine.
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Operation
f Machine operation only
g by authorized and
d
trained staff !
h
e
Fig. 85: Main menu
a Period of operation f Settings

b Next service g Adjusting the rollers
c Term of payment h Cleaning menu
d Program menu
e Maintenance menu
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Operation
12.2. CLEANING THE ROLLERS

In the cleaning menu, the rollers are cleaned by the user,

afterwards the adjustment run for the roller distance can be
started.
The cleaning guard must be mounted.

In cleaning mode, the speed is set to 30 rpm. The maximum
speed is limited to 200 rpm (70 rpm in the US). The drive torque
is limited and the force sensors for the gaps are set to a low
shutdown value in order to prevent / minimize injuries or damage
e.g. due to pulling in a cleaning towel.
NOTE
Danger of destroying components:
It is possible to skip cleaning mode and start directly with adjustment.
› ALWAYS CLEAN the machine before adjustment.
12.2.1.PRE-CLEANING THE ROLLERS

If there is still some product on the rollers, let the machine run empty as follows:
› Machine must be in gap mode.
› There is hardly any product left in gap 1.
1. Reduce speed to low speed (e.g. to 60 rpm).
2. Reduce gap 1 and gap 2 evenly to smallest gap value until gap 1 is just
about empty.
3. Stop drive.
4. Remove as much of the product as possible from scraper knife and
discharge surface of scraper socket while the scraper is swiveled into
position.
12.2.2.PREPARING FOR CLEANING

1. Dismount scraper. Use knife guard.
2. Mount splash tray.
3. Mount cleaning guard.
4. Press receipt safety button.
5. Select cleaning mode .
6. Fold cleaning towel in such a way that no corners are protruding.
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Operation
Fig. 86: Folded cleaning towel
7. Wet cleaning towel with cleaning agent.

8. Start drive and set desired speed.
e
a
f
b
Fig. 87: Menu cleaning mode
a Roller speed c Reversing mode

b Adjusting the rollers d Back to start screen
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Operation
12.2.3.CLEANING ROLLER 1
Fig. 88: Cleaning roller 1
› Place cleaning towel as far away from the roller gap as possible and move to
and fro.
12.2.4.CLEANING ROLLER 2 AND ROLLER 3
Fig. 89: Cleaning roller 2 and roller 3
› Press cleaning towel into gap 2 between roller 2 and roller 3 and move to and
fro.
› Drop the drive when the rollers have been cleaned.
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Operation
12.3. CLEANING THE SCRAPER SYSTEM

The scraper system must be cleaned after every use. In addition, it might be
necessary to clean or change the scraper system even between two passes.
This prevents mixing of the fine parts of the raw product and the already
dispersed product.
1. Dismount the scraper knife.
2. Use a spray-moistened lint-free towel to clean the individual components of
the scraper system thoroughly.
3. Mount the scraper knife.
Make sure that the scraper knife fits correctly to its lateral stop.
When using a new knife, the scraper base must be adjusted
again (see chapter 10.7 Aligning the scraper socket in parallel to
the roller)
12.4. TEMPERATURE CONTROL OF THE ROLLERS

If the rollers are temperature-controlled, the machine must be temperature-
controller for a while before adjusting the rollers.
› Scraper system is not mounted
1. Switch on the temperature control unit and set to desired temperature.
(Observe the maximum temperature change of the supply temperature in the
temperature control process: 30 °C/h (54 °F/h))!
2. Drive rollers at 30 rpm in cleaning mode and temper for approx. 1 h.
3. Then adjust the rollers.
NOTE
Danger of destroying components
If the machine is adjusted before the temperature control, the adjustment
process might not be correct any more due to thermal expansion within the
machine. Danger of damaging or destroying the rollers.
› If the machine is set to the right temperature, ALWAYS adjust after the
TEMPERATURE CONTROL.
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Operation
12.5. ADJUSTING THE ROLLERS
NOTE
Danger of destroying components:
It is possible to skip cleaning mode and start directly with adjustment.
› ALWAYS CLEAN the machine before adjustment.
› Scraper swiveled off or dismounted (knife guard mounted).

› Plastic guides dismounted.
› Select "Adjustment" .
During the adjustment process, a progress bar appears on the

display.
Fig. 90: Display during adjustment Fig. 91: Adjustment finished, confirm with
g
a Progress bar c Adjusting the rollers (repeat
b To routine operations adjustment)
› After finishing, dismount cleaning guard.

› Confirm successful adjustment with .
 The machine changes to routine operations.
A mounted cleaning guard automatically calls up the cleaning

menu, you do not access routine operations.
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Operation
12.6. DEFINING THE PRE-SETTINGS (SETUP)
In the pre-settings (setup), you set the selected working width

and the instruction for the temperature settings of an external
temperature control unit.
In general, the working width must be set matching to the used
safety device.
The instruction for the temperature settings defines a display
value on the display (only graphical and schematic view)
that the user must set at the external temperature control unit.
This function is particularly useful when running programs.
NOTE
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Operation
12.6.1.SETUP AFTER EVERY ADJUSTMENT AND BEFORE

EACH PROGRAMMING
After every adjustment of the rollers or before every creation of a program, the
setup menu is displayed automatically.
Fig. 92: Setup - Setting working width and temperature Fig. 93: Continue in routine operations
1. Select working width with control dial (a) out of 85 / 170 und 200 mm.
2. Select temperature limit with control dial (b).
3. Confirm with or . Display changes to routine operations.
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Operation
12.6.2.SELECT SETUP VIA MENU ITEM SELECT SETTING

(IN ROUTINE OPERATIONS)
1. Select menu item Settings .

2. Select Setup .
Fig. 94: Select menu selection Fig. 95: Select setup
3. Select working width with control dial (a) out of 85 / 170 und 200 mm.
4. Select temperature value with control dial (b).
Fig. 96: Setting working width and temperature Fig. 97: Back in routine operations
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Operation
5. Confirm with or .
6. Back to routine operations with .
Fig. 98: Display values for working width and temperature setting instruction for external temperature control unit
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Operation
12.7. ROUTINE OPERATIONS
b
c
a
d
g
h
j
i
Fig. 99: Display routine operations, numerical view i
a Display gap 1 h Program menu

b Gap width [Inc] i Menu DataLog
c Line pressure [N/mm] j Display process data, change
d Settings working width between graphical, schematic
e Temperature display(s) and numeric display
f Display gap 2 k Settings
g Display drive parameters
› Set the desired gap values with control dials 1 and 2 (about how to find the
correct gap values see chapter 12.8 Routine operations: Test run with
petroleum jelly).
› Pressing the corresponding control dial toggles between gap mode and force
mode.
Note: In the beginning, only operate in gap mode until you master operation in
gap mode securely.
› Use control dial 3 to set the desired speed. Start with a low speed, e.g. 80 ...
100 rpm.
› Press start button. Gap widths and speed can be varied during operation.
27891EN-900-02 / Edition 02/2017 119

Operation
› By pressing the control keys , and you can switch between

graphical, schematic and numeric display. The set parameters remain.
Fig. 100: Graphical display process parameters Fig. 101: Schematic display
120 27891EN-900-02 / Edition 02/2017

Operation
12.8. ROUTINE OPERATIONS: TEST RUN WITH

PETROLEUM JELLY
NOTE
NOTE
Roller destruction due to product film too thin or missing
› The rollers always need a product film so that the rollers do not run dry on
each other and get damaged.
› NEVER let the machine run empty uncontrolled or without product in gap
mode at gap values <20 Inc
› In force mode, keep monitoring and ensure that there is always a product
film on the rollers. Here, too, avoid uncontrolled running empty of the
machine.
12.8.1.STEP 1
1. Clean machine housing.

4. Clean machine.
5. Adjust the machine.
6. Select the desired working width (170 mm) via the operating unit.
7. Insert plastic guides 170 mm.
8. Mount safety device for nip gap (170 mm).
9. Change control into routine operations.
10. Gap settings gap 1= 10 Inc; gap 2 = 10 Inc.
12.8.2.STEP 2
11. Mount the scraper socket with scraper knife.
12. Supply product with spatula.
13. Start machine with speed 100 rpm.
14. Increase gap 1 step by step until an even product film forms. The gap
settings of gap 1 should then be around 30 Inc.
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Operation
It is important that nip gap and scraper gap are coordinated.

The product film should have an even width on all rollers and an
even thickness per roller.
The setting ratio from gap 1 to gap 2 should not exceed the value
of approx. 8:1 because else a product jam upstream of gap 2 can
arise and the product is pushed outward (see 12.8.3 Optimum
product flow)
In general, good results can be achieved with a gap ratio gap 1
: gap 2 of approx. 3:1.
15. Take up the product with the spatula and supply it back to gap 1 (nip
gap).
› To remove the product from the scraper system, use a separate

spatula so that the finely grates product is not contaminated with
raw product.
12.8.3.OPTIMUM PRODUCT FLOW
1 1
2 2
Fig. 102: Gap 1/ gap 2 too small Fig. 103: Gap 1/ gap 2 good
122 27891EN-900-02 / Edition 02/2017

Operation
Fig. 104: Ratio gap 1 / gap 2 too large
If gap 2 is set relatively too tight, the product will flow laterally
outwards and causes leaks of the plastic guides (working widths
85 mm and 170 mm) because the product is transported back from
the center roller back to gap 1 over the newly created width.
With working width 200 mm, the relatively narrow gap 2 causes the
product to pass over at the roller edges, possibly the product is
darted off by roller 3 in this area.
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Operation
12.9. REVERSE FUNCTION
In reversing mode, the rollers rotate backwards and foreign objects

or a product jam can be removed.
WARNING
In reversing mode, gap 2 becomes the nip gap. Increased risk of
being pulled in because this gap is not covered by a safety device.
fingers.
› Ensure tight-fitting clothes.
12.9.1.SEQUENCE FROM THE CLEANING MODE

› Splash tray must be mounted.
› Cleaning guard is mounted.
1. On the display, select reversing .
2. Activate key switch (b) clockwise.
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Operation
Fig. 105: Select reversing Fig. 106: Key switch must be switched
3. Unlock right latch of the cleaning guard (deactivate cleaning mode).
Fig. 107: Display: “Press start button reversing mode” Fig. 108: Deactivating cleaning mode
4. Press start button reversing mode (a).

5. The rollers rotate in reverse at 30 rpm.
6. Remove foreign object out of nip gap (gap 1).
7. Lock key switch counter-clockwise. In that position, the key can be pulled off.
8. Select Back button .
9. Lock right latch of the cleaning guard.
10. Cleaning the rollers.
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Operation
12.9.2.SEQUENCE FROM ROUTINE OPERATIONS
› Splash tray must be mounted.

› Safety device at nip gap (gap 1) is mounted.
If a foreign object was pulled in, it can be helpful to mount the

safety bridge before reversing, depending on the employed safety
bridge.
1. Select menu item Settings .

2. Select Setup .
3. On the display, select reversing .
4. Activate key switch (b) clockwise.
Fig. 109: Select “Settings” / “Setup” / “Reversing” Fig. 110: Key switch must be switched
5. Press start button reversing mode (a).

6. The rollers rotate in reverse at 30 rpm.
7. Remove foreign object out of nip gap (gap 1).
8. Lock key switch counter-clockwise. In that position, the key can be pulled off.
9. Press Back button to return to routine operations.
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Operation
12.10. CHECKING THE SAFETY DEVICES

12.10.1. PREPARING FOR CHECK

1. Dismount scraper. Use knife guard.
4. Press receipt safety button.
5. Select cleaning mode.
6. Start machine at 30 rpm.
12.10.2. CHECKS FUNCTIONS

1. Release and swivel off latch of the splash tray.
› Machine must stop by itself.
› Display splash tray on the display.
2. Lock splash tray again and press receipt safety button.
3. Start machine (30 rpm).
4. Release left latch of the cleaning guard and swivel off.
› Display safety device on display.
5. Lock cleaning guard again and press receipt safety button.
6. Start machine (30 rpm).
7. Actuate emergency stop button.
› Display emergency stop on the display.
8. Unlock emergency stop button and press receipt safety button.
› Machine is ready to start.
27891EN-900-02 / Edition 02/2017 127

Maintenance
13 MAINTENANCE
EXAKT units are, if operated properly and checked for safety, very reliable and
low-maintenance.
To ensure this, the following service and maintenance works must be done in
the specified intervals according to maintenance plan.
EXAKT recommends annual maintenance by EXAKT or by a

dealer authorized by EXAKT.
WARNING
Danger of scalding:
› Let machine cool down before maintenance.
› Disconnect machine from the mains before performing
maintenance.
› Maintenance work must only be performed by persons who are
familiar with them, have been instructed about hazards and have
the required qualification.
CAUTION
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Maintenance
13.1. CLEANING THE MACHINE HOUSING
CAUTION
When handling chemical substances such as cleaning agents,
cooling and temperature control media can cause hazards in
case of contact with skin or eyes as well as inhalation.
Provide suitable exhaust and wear safety goggles, safety gloves
and protective clothing.

processed.
manufacturers.
1. Switch off the machine via the main switch.

2. Do not clean housing parts with aggressive solvents.
3. Only moisten the dust- and lint-free towel with cleaning agent, do NOT soak.
4. Clean electric cables and parts made of rubber or EPDM with a moist cloth.
› Ensure proper disposal of the waste.
13.1.1.CLEANING THE DISPLAY OF THE OPERATING

UNIT
NOTE
Destruction of the housing seal to the display.
In case of heavy soiling, the display surface can be cleaned with solvents
such as alcohol, benzine or acetone.
› In general, only moisten the cleaning towel slightly so that no solvent can
damage the seal directly.
› Keep the contact with solvent as short as possible.
27891EN-900-02 / Edition 02/2017 129

Maintenance and care
14 MAINTENANCE AND CARE
EXAKT units are, if operated properly, very reliable and low-maintenance.

To ensure this, the following service and maintenance works must be done in
the specified intervals according to maintenance plan.
WARNING
Prior to performing service and maintenance tasks, read the
chapter safety!
Non-observance of the chapter Safety increases the risk of
injury.
Maintenance work must only be performed by persons who are
familiar with them, have been instructed about hazards and have
the required qualification.
› Prior to performing service and maintenance work, disconnect the

unit from the mains.
Basically, keep the entire system in a clean state.
130 27891EN-900-02 / Edition 02/2017

14.1. SERVICE AND MAINTENANCE PLAN
Service and maintenance Chapter

Schedule System
works
After each Plastic Check plastic guides for dirt and
use and guides wear, clean / replace if
product Rollers necessary.
change Clean rollers and run visual
check for wear.
Weekly Machine Clean machine housing. 13.1

Cleaning the
machine
housing).
Scraper Check state, replace if
socket necessary.
Splash tray Check state, replace if

necessary.
Every month Safety Check function of splash tray, 12.10

Checking the
devices function of the employed safety
safety
device for nip gap. devices
Emergency Check function. 12.10
Checking the
stop button
safety
devices
Reversing Check function. 12.9 Reverse
function
button
Temperature Check for absence of leaks.

control unit
rollers
Temperature Check transparency of the hose
control unit of the level indication (return
rollers flow trough), replace if
(pressure- necessary.
less)
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Schedule System Service and maintenance works Chapter

1500h / Machine Clean inside.
12 months
Maintenance Rollers Check geometry.
by EXAKT:
Lever Check status,

mechanics check adjustment function
Drive belt Replace, tension.
Drive belt for Replace.

tensioning /
deflector
pulleys
Electrical Safety check
operating
materials
Rotary unit Check, re-lubricate.
Every 10 Safety Replace.

years controller
EXAKT and safety
Service sensors,
emergency
stop button
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Troubleshooting
15 TROUBLESHOOTING
Description Cause Remedy

Rollers do not EMERGENCY STOP Unlock emergency stop
rotate or with actuated. button.
reduced speed. Safety device not or Check safety device, mount
incorrectly mounted. correctly.
Power supply interrupted. Switch on main switch,
establish power supply,
check fuses if necessary.
Electric assembly group Check fuses, contact Service
without power supply. if necessary.
Overload of drive. Switch off drive with stop
button. Rectify reason for
overload, restart machine
after remedy.
Thermal overload of drive. Reduce speed.
Let machine cool down at
standstill.
Overload due to highly Process product in several
viscous product. passes. Hereby, larger gap
values for the first passes.
Reduce gap widths stepwise
in the subsequent passes.
Noise from the left Drive belt insufficiently Tension or let be replaced by
machine side. tensioned or defective. EXAKT Service.
Belt tensioner or deflector replace / EXAKT Service.
pulley worn.
Toothed wheel defective. replace / EXAKT Service.
Product fineness Rollers damaged. replace / EXAKT Service.

decreases.
Product is not
remove clean.
27891EN-900-02 / Edition 02/2017 133

Troubleshooting

Product fineness Contact pressure of the Increase or reduce contact
decreases. scraper system is not set pressure (see chapter 10.5
Product is correctly (too low or too Adjusting the scraper contact
removed on one high!). pressure).
side only. Scraper knife worn. Replace.
Product is Scraper system askew. Check if all contact surfaces

removed on one at the support and the
side only. scraper are clean and free
from deposits, clean if
necessary.
Mount scraper system
correctly.
Scraper knife worn. Replace.
Scraper knife not inserted Check scraper knife and

correctly. scraper bar for dirt. Insert
scraper knife all the way to
the rear and right stop.
Roller adjustment not Clean machine and adjust
parallel. machine again.
Contact EXAKT Service if
necessary.
Product flows Plastic guides dirty or Clean, replace if necessary.
below the plastic worn.
guides Sides of plastic guides Blue marker = left side.
mismatched. Black marker = right side
134 27891EN-900-02 / Edition 02/2017

Troubleshooting

Product diverges Gap 1 (nip gap) in ratio to Reduce gap width of gap 1 or
laterally on the gap 2 too large, this increase gap width of gap 2.
rollers, possibly causes more product to the
beyond the roller pulled in than gap 2 can
ends. take over.
Removal behavior of Check function of scraper
scraper knife not perfect, knife and/or scraper system,
therefore product jam in correct contact pressure if
gap 2. necessary.
Sealing function of plastic Check function of plastic
guide not sufficient any guides, replace if necessary.
more.
Product dries out Evaporation of dispersion Use solvent dispenser for
in the area of the agent. guide lubrication (optional)
plastic guides. (see chapter 7.13.2 Optional
accessories).
27891EN-900-02 / Edition 02/2017 135

Shutting down
16 SHUTTING DOWN
16.1. SHORT-TERM SHUTTING DOWN

› Clean and store all accessories.
› Clean machine housing.
› If necessary, drain tempering fluid completely.
› Secure machine against unauthorized switching on (padlock at main switch).
› Cover machine
16.2. LONG-TERM SHUTTING DOWN

› Clean and store all accessories.
› Secure machine against unauthorized switching on (padlock at main switch) or
let it be disconnected from mains by a skilled electrician.
› Cover machine
16.3. PUTTING OUT OF OPERATION

› Clean all accessories.
› Let machine be disconnected from mains by a skilled electrician.
› Dispose of machine properly (see chapter 17.3 Disposing of unit)
136 27891EN-900-02 / Edition 02/2017

Disposal
17 DISPOSAL
17.1. DISPOSING OF PACKAGING
The packaging of the machine consists of wood, cardboard and

plastic insulation material. For disposal of the packaging, please
observe the valid local regulations.
17.2. DISPOSING OPERATING MATERIALS AND

CLEANING AGENTS
When using operating materials (e.g. tempering fluid) and/or

cleaning fluid, observe the corresponding safety data sheets and
disposal instructions of the respective manufacturer and the
local valid regulations
17.3. DISPOSING OF UNIT
Within the EU this symbol indicates that this product is not

allowed to be disposed of in household waste at the end of its
service life. Old units contain valuable materials that should be
sent for recycling to protect the environment and the health of the
public against uncontrolled waste disposal. Please therefore
dispose of old units via suitable collecting systems or send the
unit for disposal to the dealer from whom you purchased it. The
dealer will then send the unit for recycling.
Electrically operated equipment is disposed of in accordance with
national rules, which are based on the EU directive 2002/96/EC
on waste electronic and electrical equipment (WEEE).
In accordance with this directive, equipment in the business-to-
business sector, to which this product belongs, supplied after
13.08.2005 is no longer allowed to be disposed of in communal
waste disposal systems. During disposal follow the related
statutory provisions in your country. As the regulations vary from
country to country, we recommend you contact your dealer or
supplier if disposal is necessary.
In Germany the marking obligation has been in force since
23.03.2006. The manufacturer must offer an appropriate means
of return for all equipment supplied from 13.08.2005.
27891EN-900-02 / Edition 02/2017 137

Spare and wear parts
18 SPARE AND WEAR PARTS
You can order all spare parts, consumables and accessories

from your specialized supplier.
18.1. WEAR PARTS 80S PLUS, 80E PLUS
Article Description Quantity

number
Begrenzungsbacke
Plastic guide
27300
Federsatz Backenstange, 10Stk.

27305 Springs guide shaft, 10pcs.
Backenstange 170, blau

27306 Guide shaft 170, blue
Backenstange 170, schwarz

27307 Guide shaft 170, black
Backenstange 85, blau

27308 Backenstange 85, blau
Backenstange 85, schwarz

27309 Guide shaft 85, black
Abnehmermesser, Metall/ZrO2
27320 (Hybridmesser)
Scraper knife, metal/ZrO2 (hybrid knife)
Abnehmermesser,Solidknife ZrO2
27325
Scraper knife, Solidknife ZrO2
Abnehmermesser, vernickelt
27330 ist mit einer 45°-Fase
markiert (als Unterschied zu
27350)
27330
Scraper knife, nickel plated
27330 is marked with a 45°-
champfer (as distinct from
27350)
138 27891EN-900-02 / Edition 02/2017


number
Abnehmermesser, hartverchromt
27350
Scraper knife,hard-chrome plated
Abnehmermesser, PVC, rot
27360
Scraper knife, PVC, red
Abnehmermesser, Epoxy, gelb
27370
Scraper knife, epoxy, yellow
Abnehmermesser, Keramik, ZrO2
27380
Scraper knife, ceramic, ZrO2
Abnehmermesser, Keramik, Al2O3
27390
Scraper knife, ceramic, Al2O3
Begrenzungsbacke-
Stufenbacke
27700 Plastic guide-Shoulder
guide
Aufsatz f. Stufenbacke
Top f. plastic-guide
27701
Aufsatz
Stufenbacke,
Trichter
Top f. plastic-guide,
27702 hopper
Spannkonus Stufenbacke,
BG
27703 Clamping cone f. shoulder
guide
Spatel weiss, Nip Cover

27715 Spatula white, Nip Cover
27891EN-900-02 / Edition 02/2017 139


number
Spatel weiss, 185x38 mm,
10Stck.
19910
Spatula white, 185x38 mm,
10pcs.
10Stck.
19911
Spatula white, 185x51 mm,
10pcs.
10Stck.
19912 Spatula white, 185x76 mm,
10pcs.
140 27891EN-900-02 / Edition 02/2017

18.2. SPARE PARTS 80S PLUS, 80E PLUS

number
200V-Maschine (US,Jap): Sicherung
F401..403 10AT / träge (10Stck.)
B4019
200V-Machine (US,Jap): fuse
F401..403 10AT / time-lag (10pcs.)
400V-Maschine (EU): Sicherung F401..403
6,3AT / träge (10Stck.)
B4020
400V-Machine (EU): fuse
F401..403 6,3AT / time-lag (10pcs.)
Sicherung F404 2AT / träge (10Stck.)
B4021
Fuse F404 2AT / time-lag (10pcs.)
200V Maschine
Harting Wandbuchse,
6polig
27106
200V machine
Harting wall female
plug, 6-poles
200V Maschine
Harting Stecker 6-polig
200V machine
27107
Harting male plug, 6-
poles
400V Maschine
Harting Wandbuchse
6polig
27108
400V machine
Harting wall female
plug, 6-poles
400V Maschine
Harting Stecker, 6-
polig
27109
400V machine
Harting male plug, 6-
poles
27891EN-900-02 / Edition 02/2017 141


number
Abnehmersockel,
eloxiert
27341 Scraper socket,
anodized
Abnehmersockel,
PFA
27342 Scraper socket,
PFA
Klemmstreifen 1mm für

Abnehmermesser
27391
Adaptor 1mm for
scraper knife
Klemmstreifen 2mm für
Abnehmermesser
27392
Adaptor 2mm for
scraper knife
Abnehmerleiste für
Solid knife, schwarz
Scraper bar for
27393
Solid knife, black
Abnehmerleiste,
silber
Scraper bar, silver
27394
Rändelschraube M5,
Abnehmerleiste (10x)
27395
Knurled screw M5,
scraper bar (10x)
142 27891EN-900-02 / Edition 02/2017


number
Abnehmerstift 1mm / 110°
(2x) incl. 2 Schrauben
M5x35.
Scraper bolt 1mm / 110°
27397
(2x) incl. 2 screws M5x35

(2x) incl. 2 Schrauben M5x35.
Scraper bolt 4mm / 115° (2x)
27398 incl. 2 screws M5x35.

(2x) incl. 2 Schrauben
M5x35.
Scraper bolt 8mm / 120° (2x)
27399
incl. 2 screws M5x35.
Messerschutz BG
Knife guard assembly
27349
Gummi-Zargenpuffer 5mm, schwarz

B2748
Rubber buffer 5mm, black
Schlauch OD6x1x500mm, transparent für
Füllstandanzeige Rücklaufwanne (Drucklose
Kühlung)
27516
Hose OD 6x1x500mm, transparent for level
control and overflow (perssure-less
temperature control)
Schutzhaube
14250
Protective Cover
27891EN-900-02 / Edition 02/2017 143

Conformity check
19 CONFORMITY CHECK
19.1. CHECKING THE CONFORMITY
Only operate the machine after personnel authorized by EXAKT

have performs the installation and instruction.
During installation and instruction, the corresponding installation
and instruction checklists are worked off.
144 27891EN-900-02 / Edition 02/2017

Index
20 INDEX
Emergency stop button ...................... 37

A
Enable for control dial ...................... 101
Adaptor ......................................... 43, 74
Equipment variants ............................ 47
Adjustment ........................................ 114 External interface ............................... 47
Allen screwdriver ................................ 45
External interfaces (optional) ............. 38
Aluminum oxide .................................. 44
F
Antenna stop switch ........................... 37
Arrow left ........................................... 100 Fixed connection ................................ 63
Arrow right......................................... 100 Fixing screw........................................ 80
Force mode ........................................ 30
B
Fuses .................................................. 38
Base unit ............................................. 44
G
C
Gap mode ........................................... 29
Center display field ........................... 101 Glysantin® G48® .............................. 39
Center of gravity ........................... 51, 55
Guide shaft ......................................... 50
Ceramic scraper knife .................. 73, 79
Guide tube .......................................... 86
Clamping cone for shoulder guide ..... 88 Gummi-Zargenpuffer 5mm, schwarz
Cleaning .............................................. 29
...................................................... 143
Cleaning guard ............................. 29, 44
H
Cleaning menu ................................. 110
Cleaning mode .........................100, 110 Hand ................................................... 77
Cleaning towel .................................. 111 Hard chrome plated steel ................... 44
Clevis .................................................. 43 HARTING connector .......................... 65
Combination scraper knife – scraper Heavy duty connector ........................ 64
bar - adaptor ................................... 75 Home button ..................................... 100
Connection for roller temperature Hopper ................................................ 48
control ............................................. 38 Hopper base ....................................... 91
Contact pressure ................................ 77 Hopper for working width 170 mm ..... 91
Control dial ........................................ 100 Hopper for working width 200 mm ..... 93
Control keys ..............................100, 101 Hose ................................................... 68
Corrosion protection ........................... 39 Hose clamp......................................... 68
D I
Declaration of conformity ................. 149 Inlet flow.............................................. 38

Dispenser ............................................ 50 Inlet flow nozzle .................................. 68
Disposal ............................................ 137 Inlet flow temperature......................... 69
Intended use ....................................... 18
E
Interfaces ............................................ 47
Electrical connection .......................... 47
Emergency stop.................................. 31
27891EN-900-02 / Edition 02/2017 145

Index
K Product flow ...................................... 122

Protective cover.................................. 50
Key switch ........................................... 37
Pull-in protection................................. 48
Key switch „Release Reverse“ ........... 37
Pushbutton ....................................... 100
Knife edge ........................................... 74
Knife guard ................................... 29, 76 R
L Receipt safety ..................................... 98

Receipt safety button ......................... 37
Latch ................................................... 82
Recessed grips................................... 57
Level indication return flow................. 38
Return flow ......................................... 38
Level indication return flow trough ..... 40
Return flow nozzle .............................. 68
Load traverse ...................................... 43
Reverse function .............................. 124
Locking cock ....................................... 38
Reversing ........................................... 98
Locking lever ................................. 37, 82
Roller materials .................................. 47
Lower display field ............................ 101
Roller temperature control ................. 39
M Rotary unit .......................................... 39
Main switch ......................................... 38 Routine operations ............................. 33
Maintenance ..................................... 130
S
Manufacturer address .......................... 6
Safety.................................................. 47
Mixing .................................................. 29
Safety bridge ...................................... 48
N
Safety controller ............................... 101
Network cable ..................................... 61 Safety device ...................................... 44
Nip Cover ............................................ 48 Safety device gap 1............................ 28
Nip gap ................................................ 44 Safety device nip gap ......................... 90
Safety devices .................................... 32
O
Safety guard ....................................... 91
OK button .......................................... 100 Safety sensor ..................................... 32
Operating instructions ........................ 46 Safety symbols ..................................... 9
Operating panel .................................. 98 Scale ............................................. 37, 77
Operating unit ..................................... 37 Scale value ......................................... 77
Optimum product flow ...................... 122 Scraper angle ..................................... 81
Ordering spare parts ............................ 6 Scraper bar ......................................... 74
P Scraper base ...................................... 80
Scraper bolt ........................................ 81
Packaging ......................................... 137
Scraper bolt for scraper angle ........... 45
Plastic guide ....................................... 28
Scraper constriction ........................... 50
Plastic guide - shoulder guide ............ 88
Scraper contact pressure ........... 77, 134
Plastic guides...................................... 44
Scraper knife .................... 28, 43, 45, 72
Plastic spatula..................................... 50
Scraper knife types ............................ 72
Pressure cooling ................................. 39
Scraper lever ................................ 37, 82
Pressureless cooling .......................... 39
Scraper socket ............................. 27, 45
146 27891EN-900-02 / Edition 02/2017

Index
Scraper system ................................... 43 Stop button ......................................... 37

Service questions ................................. 6
T
Setting dial for scraper force ........ 37, 77
Temperature control ........................... 68
Setup site ............................................ 58
Temperature control of the rollers ... 113
Sheet with safety instructions............. 46
Shutting down ................................... 136 Temperature control unit .................... 68
Temperature sensor ........................... 40
Silicon carbide .............................. 44, 47
Tempering fluid................................... 36
Solvent dispenser ............................... 50
Spare and wear parts ....................... 138 TILT sensor .................................. 51, 52
Toolbar.............................................. 101
Spatula .............................................. 122
Top for shoulder guide ....................... 88
Splash guard................................. 49, 94
Splash guards for inner side paneling 95 Tungsten carbide coated steel .......... 44
Splash guards for working width U

200 mm ........................................... 94
Upper display field ............................ 101
Splash tray .................................... 28, 45
USB interface ................................... 100
Start button ......................................... 37
Start button reversing mode ............... 37 W
Status messages .............................. 101 Warranty conditions ......................... 148

Steel, hard chrome plated .................. 47 Working width ............................... 85, 92
Steel, tungsten carbide coated .......... 47
27891EN-900-02 / Edition 02/2017 147

Annex
21 ANNEX
21.1. WARRANTY CONDITIONS
Manufacturer's warranty becomes void in case of improper use:

› Non-observance of this manual.
› Assigning non-qualified personnel.
› Unauthorized modifications to the unit and its components.
The manufacturer is not liable for resulting damage.
NOTE
Impairment of unit function due to using incorrect spare parts or operating
materials; the manufacturer warranty becomes void!
When using not approved spare parts or operating materials, the unit
function is not ensured, warranty becomes void.
Only use original or EXAKT-approved spare parts and operating materials.
148 27891EN-900-02 / Edition 02/2017

Annex
21.2. DECLARATION OF CONFORMITY
EC Declaration of Conformity
in the sense of: EC Machinery Directive (98/37/EC)

EC Low Voltage Directive (73/23/EEC)
EMC Directive (89/336/EEC)
Herewith we declare: EXAKT-Apparatebau GmbH & Co. KG

Robert-Koch-Str. 5, 22851 Norderstedt
that the machine designated below due to its conception and design in the
version put onto the market by use meets the relevant basic safety and health
requirements of the EC Directive.
In case of modifications to the machine not approved by us, this declaration
becomes void.
Designation of the EXAKT Belt System: 300, 310, 311
machine: CL / CLV / CP / CPV
Applied harmonized EN 60335-1 1988

standards: EN 60204-1 1992
EN 50081-2: 1992
EN 50082-2: 1995
IEC 1000-4-2: 1995
ENV 50140: 1993
IEC 1000-4-4: 1995
ENV 50141 1993
VDE 0701
EN 50082-2 (series with frequency converter)
The product meets the requirements of the German Machine Safety Code.
27891EN-900-02 / Edition 02/2017 149

EXAKT
ADVANCED TECHNOLOGIES
GMBH
Robert-Koch-Straße 5
D-22851 Norderstedt/Germany
T +49 (0)40.52 95 60-0
F +49 (0)40.5 24 99 59
info@exakt.de · www.exakt.de

06 Ba Exakt 80eplus Englisch

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Table of Contents

THREE ROLLER MILL

Document number / Edition

2.2. Service and ordering spare parts 6

5.9.2. Type plate of operating unit 23

27891EN-900-02 / Edition 02/2017 1

7.6. Safety marks 34

7.6.2. Danger of cuts 34

7.9. Scraper system 43

2 27891EN-900-02 / Edition 02/2017

9.4.4. Connection variant 3: Connection via three-poles standard

9.5. Connecting the roller temperature control 68

9.5.2. With pressureless cooling 69

27891EN-900-02 / Edition 02/2017 3

10.15. Mounting hopper for working width 200 mm 93

11.5. Program structure 105

12.2.2. Preparing for cleaning 110

12.3. Cleaning the scraper system 113

12.7. Routine operations 119

12.8.3. Optimum product flow 122

4 27891EN-900-02 / Edition 02/2017

27891EN-900-02 / Edition 02/2017 5

2.1. MANUFACTURER ADDRESS

EXAKT Advanced Technologies GmbH

Phone: +49 (0) 40 / 529 560 - 0

© EXAKT Advanced Technologies GmbH, Norderstedt

Layout:: EXAKT Advanced Technologies GmbH

Subject to change without notice!

2.2. SERVICE AND ORDERING SPARE PARTS

6 27891EN-900-02 / Edition 02/2017

3 INSTALLATION INFORMATION IN ADVANCE

We additionally recommend to read the entire operating

Especially when Chapter

27891EN-900-02 / Edition 02/2017 7

Link back to chapter 3 Installation information in advance

4.1. GENERAL INFORMATION CONCERNING SAFETY

Every persons appointed to install, commission, operate, maintain and service

Here you find important background information and

8 27891EN-900-02 / Edition 02/2017

4.2. SAFETY SYMBOLS

Warning of rollers rotating reversely

Danger of hand injuries

Warning of toxic substances

Warnung of explosive substances

Wear safety gloves

Wear foot protection

Wear eye protection

Wear protective clothing

27891EN-900-02 / Edition 02/2017 9

Wear protective apron / lab coat

Disconnect machine from the mains

Read operating instructions

Reference to other documents

4.3. GRAPHICAL CONVENTIONS

10 27891EN-900-02 / Edition 02/2017

4.5. SELECTION OF LOCATION

The unit must be placed horizontally.

When selecting the location of installation, observe the corresponding safety

27891EN-900-02 / Edition 02/2017 11