Hand Extruder ME-40/MA-40
Contents
1. Page 22 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH IN LI IN I Plastic Welding Technology Parts list of MA 40 B hand extruder 230 Volts K02747 Item No Qty Ident No Designation 1 25 K00542 Grub screw M6x 10 5 86 1 K02591 Extruder body MA E 40 114 1 K02150 Ring for handle MA E 60 ME 40 MA 40 Edition 09 2002 Rev 01 Seite 23 36 Hand Extruder ME 40 MA 40 Parts list of MA 40 B hand extruder 230 Volts K02747 Item No Qty Ident No Designation 130 1 K02280 Casing lower section MA E 60 230 400V 49 1 1 K02966 Joint ring MA E 40 u 60 Page 24 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH LO ew Z0 60 03 0 0v VW v8 LO S DL t 9 Cel T SC LC 28 t l Li S bel LOL 49 QU tel lA Seite 25 36 C2. 1 MAIS 1 14 Overall drawing of MA 40 D hand extruder with integrated air supply Edition 09 2002 Rev 01 ME 40 MA 40 Hand Extruder ME 40 MA 40 Parts list of MA 40 D hand extruder 230 Volts K02748 Item No Qty Ident No Designation 1 25 K00542 Grub screw M6x 10 5 86 1 K02591 Extruder body 114 1 K02150 Ring for handle MA E 60 Page 26 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH IN LI IN I Plastic Welding Technology Parts list of MA 40 D hand extruder 230 Volts K02748 Item No Qty Ident No Designation 130 1 K02280 Casing lower section MA E 60 230 400V 49 1 1 K02966 Joint ring MA E 40 u 60 ME 40 MA 40 Edition 09 2002 Rev 01 Seite 27 36 Hand Extruder ME 40 MA 40 Exploded view of hot air blower for MA 40 B D hand extruder Lectron Arikel Nr 113 091 Munsch Page 28 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH IN LI IN I Plastic Welding Technology
3. BA ME 40 B DR d IS 4X 2 L X ES cy W ess I Vi gt 7 7 7 7 7 7 j 7 j LLY Y N Lf ERES AE HAL 7 AUI d d f d f j gi Fi f n x x li V WS Lt 7 m 4 N zu Ee m yuu LB LECH MM Wu A NA y rn ME 40 MA 40 Edition 09 2002 Rev 01 Seite 17 36 Hand Extruder ME
4. r E Z o E A 2 SI Eis t d L SE ES ENO E E N MS H DOD 777 7 7 IN 1 7 m I ES Tw S TC ms CA po Gel S CH Cm GE S 3 x D ol Sch V a FH E c wb ooh AM MMT E CLE 2 ch EE EN SH ca SS 674 87 c LJ LA y ur x pos yg iyoupgiemuss ra T A SC dd d 09 V SES V buipje Gg 1 Gg d U
5. Parts list of hot air blower for MA 40 B D hand extruder Item Qty Art Designation 1 1 6 100 299 Oval head screw M4 x 10 1 1 GO NO gt 12 1 101 251 Steel sleeve 15 3 100 284 Self tapping oval head screw M4 x 14 1 101 776 Heating element type 32 230V 2200W Oo N 30 1 104 272 Counter nut PA PG9 black ME 40 MA 40 Edition 09 2002 Rev 01 Seite 29 36 Hand Extruder ME 40 MA 40 7 Malfunctions Causes and Remedies 7 1 Trouble shooting The following table lists potential malfunctions of the hand extruder together with likely causes and their remedies fault diagnosis chart If malfunctions occur which are not covered here or which cannot be traced back to the cause indicated please contact MUNSCH Kunststoff Schwei technik GmbH Drive motor does not start 5 6 9 10 11 12 14 15 16 17 18 19 21 23 25 Drive motor switches off 5 6 9 10 11 12 14 15 16 17 18 19 21 23 25 No welding rod feed 1 16 17 20 26 No weld material conveyed out of the welding shoe 1 16 26 Weld material feed rate decreases during operation 1 14 16 No compressed air 13 Failure of integrated air supply 22 5 No hot air Hot air temperature below setpoint 2 3 4 8 10 18 22 14 Weld material temperature below setpoint 2 3 9 11 14 24 Extruder remains cold 2 3 12 22 24 Temperat
6. gy U Operating Instructions Type ME 40 40 Serial No 230 Volts P O No P O date K02845 for Hand Extruder Ident No K02746 K02747 K02748 A These operating instructions contain important information to be observed for hand extruder operation and maintenance It is therefore imperative that the operating instructions are read and their contents is fully understood by the operator before the hand extruder is being placed in service MUNSCH Kunststoff Schwei technik GmbH Phone 49 0 26 23 8 98 0 Im Staudchen e D 56235 Ransbach Baumbach Fax 49 0 26 23 8 98 21 P Box 142 e D 56221 Ransbach Baumbach Internet http www munsch de Germany E Mail munsch munsch de MUNSCH Kunststoff Schwei technik GmbH Edition 09 2002 Rev 01 Page 1 36 Hand Extruder ME 40 MA 40 Scope of delivery Please check if the delivery is complete The delivery comprises 1 hand extruder 1 extruder stand 1 handle 1 hot air hood 1 welding shoe shaped 3 air nozzles Page 2 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH PA U AN SS C Plastic Welding Technology Table of Contents t GENERAL on 5 2 A 3 A EE 5 2 1 IDENTIFICATION OF INFORMATION IN THE OPERATING INSTRUCTIONS 6 2 2 PERSONNEL QUALIFICATION AND TRAINING 6 2 3 RISKS RESULTING FROM NON OBSERVANCE OF THE SAFETY INSTRUCTIONS 6 24
7. Length Minimum cross section m inus So 9 1 for230 V AC Page 6 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH LJ N SS C Si Plastic Welding Technology e Extension cables must be certified for the respective service conditions e g outdoor The hand extruder must not be used in service and identified accordingly explosion hazard areas or flammable environments Always handle the connecting cable with care Make sure to stand on a firm base when Do not kink the connecting cable operating the hand extruder Do not place any items on the cable Do not jam or squeeze the connecting cable nor pull it over sharp edges Protect the connecting cable from moisture Connecting cable welding rod and hose for external air supply if applicable must be freely movable and must not disturb the operator or third persons in their work e IN Do not touch mains connector or e Hold and touch hand extruder only on connecting cable with wet hands Hold the cable the handles provided for this purpose os is i Do not touch bare metal parts including hot unplugging it air hood either with or without gloves These parts reach temperatures of up to 350 C e CAUTION If a power set is used for power Attachments may be damaged by the weight of supply the set must have the following rated the hand extruder or may be impaired in their output function Ba
8. The safety precautions described under chapters Safety and Malfunctions Causes and Remedies must be adhered to For dismantling and assembly the associated overall drawing must be strictly observed 6 2 1 ME 40 hand extruder with external air supply Overall drawing No BA ME 40B DR 09 02 Rev 01 Parts list ME 40 B K02746 Exploded view of air heater Parts list of air heater 6 2 2 MA 40 hand extruder with integrated air supply Overall drawing No BA MA 40B ER 09 02 Rev 01 Parts list MA 40 B K02747 Overall drawing No BA MA 40D EO 09 02 Rev 01 Parts list MA 40 D K02748 Exploded view of hot air blower Parts list of hot air blower Page 16 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH NNN Plastic Welding Technology Overall drawing of ME 40 B hand extruder with external air supply Lufttemperatur air Lf Lf EN setemperatur melt B ME oder or ee SchweiBdraht 84 welding rod 5 SchweiBdraht 5 welding rod
9. 01 Seite 31 36 Hand Extruder ME 40 MA 40 Possible causes Remedies Actual value out of range Although this is no fault the message is displayed if the out of range actual value is smaller than the display range Smaller than 1999 Actual value out of range Although this is no fault the message is displayed if the out of range actual value is greater than the display range Greater than 9999 1 Consult MUNSCH Kunststoff Schwei technik GmbH 2 Only MA 40 3 Only ME 40 8 Technical Data Type designation ME 40 MA 40 5 mm 4 0 kg h PP 4 0 kg h PE Q 5 mm 4 0 kg h PP 4 0 kg h PE Service range Wall thicknesses 8 30 mm and film Wall thicknesses 8 30 mm and film welds welds Weight 7 9 kg 8 0 kg Drive 230 V AC with speed control external 230 V AC with speed control external powerbox powerbox Extruder heating 650 W 1650 W 2000 W 2200 W Air supply Integrated air supply Air consumption at least 300 l min at 0 4 bar at least 300 l min temperature control and set point display set point display and set point display set point display Cold start protection Temperature controlled start interlock Temperature controlled start interlock as a function of weld material and as a function of weld material and preheating air temperatures preheating air temperatures Page 32 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH IN LI IN ki Plastic W
10. EG EN 55014 2 lt EU Low Voltage Directive 73 23 EWG lt EN 61000 3 2 EU Directive EMV 89 336 EWG lt EN 61000 3 3 D EN 55011 EN 55014 1 Conformance of this industrial tool with above standards is subject to the condition that it is used in accordance with the contractually agreed service conditions the responsibility for which shall rest with the user Modifications to the machine unit or the use of the machine unit for applications other than the intended service will make this declaration null and void unless expressly approved in writing by the manufacturer Ransbach Baumbach May 2002 Dipl Ing Stefan Munsch Managing Director Page 4 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH NA U AN SS C Plastic Welding Technology 1 General AN These operating instructions must always be available at the place of use of the hand extruder The objective of these operating instructions is to support operators in familiarizing themselves with the hand extruder and in using its functions for the intended service The operating instructions provide important information for the safe workmanlike and economical operation of the hand extruder Their observance helps avoid danger minimize repair costs and downtimes enhance reliability and extend the service life of the hand extruder Any person performing work with on the hand extruder is requi
11. Kunststoff Schwei technik GmbH LJ N SS C Si Plastic Welding Technology CAUTION Once air exits preheating nozzle 4 the heating systems air material temperature may be switched on via switch 124 Istwert actual value Istwert actual value Ct Sollwert setpoint Sollwert setpoint 22 eM V c 4 4 ee AC vm Massetemperatur melt Lufttemperatur air 7 Da eg B N nn D em een en I CO Ice REEL On NA o For operation of the temperature controller see sub section 5 5 Adjust temperature controller For temperature values see page 15 Temperatures for ME 40 MA 40 The hand extruder reaches its operating temperature after approx 15 20 minutes Set the maximum speed on the drive and preset the speed on the power box A The hand extruder may now only be held and touched on the handles Pa C 002 0001 CAUTION The start switch of the drive unit may only be operated when the operating temperature has been reached Otherwise the hand extruder may be damaged by solidified weld material present in the extruder The hand extruder is equipped with a temperature controlled interlock which prevents drive starting before the melting temperature is reached Apart from the temperature controlled start interlock the brushless drive is equipped with a
12. is remedied The period of limitation shall be suspended for such claim Page 34 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH gyunscon Plastic Welding Technology ME 40 MA 40 Edition 09 2002 Rev 01 Seite 35 36 Hand Extruder ME 40 MA 40 MUNSCH Kunststoff Schwei technik GmbH Im Staudchen e D 56235 Ransbach Baumbach P O Box 142 e D 56221 Ransbach Baumbach Germany Phone 49 0 26 23 8 98 0 Fax 49 0 26 23 8 98 21 Internet http www munsch de E mail munsch munsch de Page 36 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH
13. safe to touch temperature using the air supply system Do not operate dismantle or carry out modifications on the hand extruder if connecting cable or mains connector are defective safety devices are damaged foreign matter or liquid has penetrated into the hand extruder the unit does not work properly or there are unusual changes in the operating mode IN Never allow the hand extruder to come into contact with water as this may cause a hazard to persons damage to the equipment as well as a short circuit 2 6 Safety instructions for maintenance inspection and mounting The Operator is responsible for ensuring that all maintenance inspection and mounting work is performed by authorised and qualified personnel who is thoroughly familiar with the operating instructions e As a rule the hand extruder must be shut down and the mains connector unplugged before carrying out any work on the unit The shutoff procedure for the hand extruder must be strictly followed e Electrical hazards are to be ruled out for details see VDE regulations and standards of your local electric utility for instance e IN VDE 0701 IEC 335 prescribes the measurement of the protective conductor resistance insulation resistance and leakage current after any maintenance work on or modifications of electrical equipment Furthermore a visual inspection of the unit and its connecting cable as well as a voltage and power measuremen
14. 40 MA 40 Parts list of ME 40 B hand extruder 230 Volts K02746 Item No Qty Ident No Designation 54 1 K01484 Screwed cable guide PG 16 1 110 1 K02636 Holder 45 MA E 40 112 1 K02524 Holder DR ME 40 120 1 K02551 Heating cartridge 30x40x170 MA E 40 Page 18 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH IN LI IN SS CC I Plastic Welding Technology Parts list of ME 40 B hand extruder 230 Volts K02746 Item No Qty Ident No Designation 49 1 1 K02966 Joint ring MA E 40 u 60 ME 40 MA 40 Edition 09 2002 Rev 01 Seite 19 36 Hand Extruder ME 40 MA 40 Exploded view of air heater for ME 40 hand extruder Drawing in preparation Page 20 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH PA LJ IN SS Ch ayauNS Ch Parts list of air heater for ME 40 hand extruder Spare parts list in preparation ME 40 MA 40 Edition 09 2002 Rev 01 Seite 21 36 Hand Extruder ME 40 MA 40 Overall drawing of MA 40 B hand extruder with integrated air supply Lufttem Massetemperatur melt peratur air Kunststoff Schwei technik
15. SAFE WORKING PRACTICES nen nn ee ee ee 6 2 5 SAFETY INSTRUCTIONS FOR OPERATOR USER cscccccsececcsececceececceeeccanecsceeeeccueescceneeceeecesaesesceeeeceeesueeesceess 6 2 6 SAFETY INSTRUCTIONS FOR MAINTENANCE INSPECTION AND MOUNTING nnn nnns 8 2 UNAUTHORISED MODIFICATIONS AND SPARE PARTS 8 3 TRANSPORT AND STORAGE u een 9 OMEN roli se EE EE ne ee 9 ol co AM H 9 RETORN TOMON CH ee 9 4 PRODUCT DESCRIP TION eege 10 dob ALLOWABLE SERVICE RANGE se une 10 42 OGENERAE DESCRIPTION ee ee 10 9 SIARTURANDSHUTOFF MM 11 Il ET ea 11 9 2 PREPARA THON EE ee ee ae 11 5 3 STARTING THE HAND EXTRUDER ege 12 5 4 WELDING WITH THE HAND ESTRUDER 13 5 4 1 WEIGING TOG serere inea EEEE EREE EEEE EE AEE E AEE 13 5 4 2 Replacement and ageing of welding mod 13 5 4 3 Welding direction rate err rre 14 5 4 4 Interruption OF WORK EE 14 E AO E 14 5 4 6 Trans POL SION AGC NIENTE ERROR 15 5 5 ADJUST TEMPERATURE CONTROLLER 5 e inea ndnsas sas pw ec n FII Vaso sence nen anne cect rci R
16. Welding Technology 5 4 5 2 Hand extruder with external air supply Type ME 40 e Switch off heating systems via switch 124 e Unplug mains connector of hand extruder Maintain the air supply after switching off the hand extruder until the unit has completely cooled down Never use water or another coolant to accelerate the cooling process 5 4 6 Transport storage Observe instructions under chapter Transport storage N Never use water or another coolant to accelerate the cooling process 5 5 Adjust temperature controller The weld material and air temperatures are adjusted at the manufacturer s workshops as shown in the temperature table for the ME 40 and MA 40 hand extruders Temperatures for ME 40 MA 40 Material Material Air temperature temperature PP 200 240 C X 250 3007C X If other temperatures are required they can be set with the aid of the temperature controller 5 5 1 Adjust temperature controller Istwert actu al value Istwert actu al value Sollwert setpoint Sollwert setpoint Massetemperatur melt T i N N A Q Vdus l A Rc D Operating panel S Temperature display C or F Actual value display red Display for controller output OUT heating on Setpoint display gre
17. carrying out any work on it to mount and activate all safety and protection devices immediately after completion of the work During maintenance and repair work make sure that the hand extruder and its individual components are firmly positioned In addition to the operating instructions and the national and local accident prevention regulations applicable at the place of use the acknowledged technical rules for safe and proper working practices are to be observed Any working practices posing a safety risk are prohibited AN Activities outside the above scope may only be performed at the manufacturer s workshop 6 1 Maintenance Inspection of hand extruder ME 40 MA 40 e CAUTION After approx 500 operating hours the hand extruder including drive unit must be thoroughly cleaned and inspected This work may only be carried out at the manufacturer s workshops e CAUTION Cables switches plug in connections must be inspected by qualified staff every three months regulation to VBG4 the inspection results must be documented e Only original spare parts should be used 6 2 Dismantling Prior to dismantling the hand extruder pull the mains connector The hand extruder must be at ambient temperature Damaged mains connection cables and or interconnecting cables 142 must be replaced lines pose a hazard to life and limb Cable replacement is to be carried out by qualified electricians only
18. ces for the purchased article The Purchaser shall give written notice of defects to the respective company immediately after such defects have been identified or have such defects registered by the respective company 3 2 Defects shall be promptly remedied in accordance with the technical requirements by either replacement or repair of the defective parts the cost of the remedial work being for the account of the Manufacturer Replaced parts shall become the property of the Manufacturer If as a result of the remedial work additional maintenance measures are prescribed by the Manufacturer the resulting costs including the costs of materials and lubricants shall be for the Manufacturer s account 3 3 For replacement parts installed within the scope of the remedial work a new 6 months warranty period shall begin from the date of replacement 3 4 For the warranty to become effective this warranty certificate must be produced before each repair 4 Ifthe defect cannot be remedied or if the Purchaser cannot be reasonably expected to accept further attempts at making good the defect the Purchaser may demand annulment cancellation of the purchase contract or a price reduction reduction of compensation in lieu of remedial work In such a case the Purchaser shall no be entitled to any replacement 5 Manufacturer s warranty obligations shall not be affected by a change in ownership of the purchased article 6 Expressly excluded f
19. date output are set at the power box The Powerbox has three LEDs red undervoltage defective yellow temporary drive overload green normal operation For both types of hand extruder the following parameters can be freely selected welding rate hot air temperature temperature and weld material throughput the throughput can be controlled downwards from the maximum value firstly by using 4 mm instead of 5 mm welding rod secondly by reducing the speed with the aid of the rotary button on the Powerbox or the fine tuning button of the drive When reducing the speed care must be taken to maintain the minimum extrudate throughput welding rod 4 mm minimum 1 6 kg h welding rod 2 5 mm minimum 2 7 kg h CAUTION If the speed is too low there is a risk of drive overheating Driven by a powerful electric motor 1 the welding rod 2 is fed into the extruder 3 and granulated by the extruder screw in the process The screw then forces the granulate into the extruder nozzle melting it to a homogeneous completely plastified welding material As the molten material exits the extruder nozzle it is moulded to the geometry of the weld to be deposited by a welding shoe 4 Preheating of the base material to be joined is achieved by preheating nozzle 5 which is supplied from an integrated hot air unit 6 Air is either supplied from an external compressor or an integrated blower Page 10 36 Editio
20. e 15 5 5 1 Adjust temperature Contiroller cessi isseisesesse sees sense nen anu anne hahahaha sa aaa 15 6 16 6 1 OF HAND EXTRUDER 40 40 16 0 2 16 6 2 1 ME 40 hand extruder with external air suppl 16 6 2 2 40 hand extruder with integrated air Supp 16 7 MALFUNCTIONS CAUSES AND 30 EMI oU E eou c 30 1 2 FAUT DIAGNOSIS risto 30 MEE L8 3 974 Tu RE 32 ME 40 MA 40 Edition 09 2002 Rev 01 Seite 3 36 Hand Extruder ME 40 MA 40 Konformitatserklarung des Herstellers im Sinne der EG Maschinenrichtlinie 98 37 EG Anhang II B Declaration of Conformity by the Manufacturer as defined by machinery directive 98 37 EEC Annex II B MUNSCH Kunststoff Schwei technik GmbH Im Staudchen D 56235 Ransbach Baumbach hereby declares on its own behalf and responsibility that the hand extruder Machine type Hand Extruder Design designation ME 40 MA 40 to which this declaration refers conforms to the following standards codes or regulations lt EU Machinery Directive 98 37
21. e e Under the pressure of the discharging weld material the welding shoe and the hand extruder are moved in welding direction e See DVS regulations for welding rate D02 0026 5 4 4 Interruption of work Observe chapter Safety Do not leave the hand extruder unattended Maintain the air supply e When interrupting the welding work switch off the drive unit and deposit the hand extruder as shown below 5 4 5 Shutoff AN Observe chapter Safety e After finishing the welding work switch off the drive unit and deposit the hand extruder as shown for illustration see subsection 5 4 4 Do leave hand extruder unattended 5 4 5 1 Hand extruder with integrated air supply Type MA 40 e Switch off heating systems via switch 124 Istwert actual value Istwert actual value Sollwert setpoint Sollwert setpoint N QUT YM 7 ZA op AL A AY CH E LH MMM 2277 ee c Si Masselemperatur mell Lufttemperatur air e Maintain the air supply after switching off the hand extruder until the unit has completely cooled down e Unplug mains connector Never use water or another coolant to accelerate the cooling process Page 14 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH NA U AN SS C Plastic
22. e to observe the safety instructions may cause hazards to person and the environment as well as damage to the hand extruder Moreover non compliance with the safety instructions may lead to the forfeiture of any damages Non compliance with the safety instructions may in particular involve the following risks e failure of important hand extruder functions e hazards to persons due to electrical and mechanical impacts and risk of burns e hazards to the environment due to vapors of hazardous substances e risk of fire 2 4 Safe working practices The safety instructions given in these operating instructions the applicable national accident prevention regulations and any existing in company work operating and safety instructions issued by the Operator are to be followed 2 5 Safety instructions for operator user e Prior to startup it is to be checked if the mains voltage and frequency correspond with the data indicated on the type tag The allowable tolerances are 5 for voltage and or 2 for frequency According to VDE 0100 855 the hand extruder is to be operated via a residual current operated circuit breaker or an isolating transformer e CAUTION During hand extruder operation under load a voltage of at least 230 V must be available at the mains connector e extension cable is used the minimum conductor cross section must be observed Use extension cables with protective conductors only
23. elding Technology Warranty Certificate Name and address of Purchaser Type of unit Hand extruder Type designation ME 40 MA 40 Serial number Purchase order date Your Warranty MUNSCH Kunststoff Schwei technik GmbH hereby warrants the unit to be free from defects in material and workmanship from the date of its first acquisition Should deficiencies resulting from defects in materials or workmanship be identified during the warranty period the dealers will in accordance with the following conditions repair the unit or at their discretion replace the unit or the defective components without charging labour or material costs Stamp and signature of dealer ME 40 MA 40 Edition 09 2002 Rev 01 Seite 33 36 Hand Extruder ME 40 MA 40 Warranty 1 The manufacturer warrants freedom from defects in materials and workmanship and state of the art performance of the purchased article for a period of six months from the date of delivery 2 The Purchaser shall check the article delivered for completeness and freedom from defects immediately after receipt 3 Purchaser is entitled to the making good of defects and any resulting damage to other parts of the purchased article remedial work The procedure for claims under this warranty shall be as follows 3 1 The Purchaser may assert claims under this warranty either with his dealer or with a company authorized by the manufacturer to provide servi
24. en Key Up temperature setpoint increases Key Down temperature setpoint is reduced controller lock do not press key CAUTION controller lock do not press key lights up if the start up temperature is reached gt Display for start up temperature AL This display lights up when the start release temperature is reached The start release temperature has been set to a level of 30 C below the setpoint at the manufacturer s works The drive can be started once the setpoint temperatures for air and weld material have been reached ME 40 MA 40 Edition 09 2002 Rev 01 Seite 15 36 Hand Extruder ME 40 MA 40 6 Maintenance Inspection IN Pull mains connector before carrying out maintenance and repair work on the unit Maintenance and repair work on electrical tools may only be carried out by qualified electricians AN The hand extruder together with the hot air hood must have cooled down to safe to touch temperature Observe the instructions under chapter Safety Maintenance and repair work should only be carried out by qualified personnel or by our service staff To ensure the proper function of the hand extruder over its entire service life for its intended service we recommend to have all maintenance inspection and mounting work carried out by authorised and qualified personnel who are thoroughly familiar with the operating instructions to always shut down the unit before
25. ety These operating instructions contain important information to be followed for operation and maintenance For this reason it is imperative that they be read by the responsible specialist personnel operators before mounting and starting up of the hand extruder and that they are permanently available at the place of use Operating reliability of the hand extruder presupposes that the instructions under Chapter 1 General herein are complied with In no case must the limit values indicated be violated The hand extruders are in conformance with all applicable standards and meet the prescribed limit values with regard to EMC electromagnetic discharges and interference immunity provided they are not defective and have not been modified Nevertheless they emit electromagnetic fields within the acceptable limits Electromagnetic fields may interfere with the operation of vital electronic devices e g cardiac pacemakers Users of cardiac pacemakers should consult their physician before using the machine In addition to the operating instructions and the national and local accident prevention regulations applicable at the place of use the acknowledged technical rules for safe and proper working practices are to be observed Apart from the safety instructions contained in this chapter also the special safety instructions given under the respective subsections must be adhered to Any working practices posing a safety risk is pro
26. fe to touch These parts reach temperatures of up to 350 C during operation 5 A D02 0001 e Never transport or store the hand extruder in such a way that the attachments are exposed to mechanical loads If parts have been removed for transport purposes mount and fasten them carefully before restarting the unit MUNSCH s original packaging or the transport cases offered by MUNSCH are recommended for transport ME 40 MA 40 Edition 09 2002 Rev 01 Seite 9 36 Hand Extruder ME 40 MA 40 4 Product Description 4 1 Allowable service range The allowable service range of the hand extruder is defined by the data on the type tag and the service range limits indicated in these operating instructions CAUTION Operation of the hand extruder outside the allowable service range stated in these operating instructions is not allowed without the manufacturer s prior approval 4 2 General Description Type ME 40 is a hand extruder with external air supply Type MA 40 is a hand extruder with integrated air supply Autoair I mo JE CY N 2 Powerbox WX 2PBMU Powerbox WX 2PBMU is required for the operation of the hand extruder It consists of a power pack frequency inverter and an EMC filter The drive speed and hence the extru
27. hibited ME 40 MA 40 Edition 09 2002 Rev 01 Seite 5 36 Hand Extruder ME 40 MA 40 2 1 Identification of information in the operating instructions In these operating instructions safety instructions whose non observance may cause hazards to persons are identified with hazard symbol according to DIN 4844 W 9 for general hazards and with hazard symbol according to DIN 4844 W 8 for electrical hazards Safety instructions whose non observance may cause damage to the hand extruder and its functions are marked with CAUTION Instructions directly indicated on the hand extruder must be strictly followed and kept in a fully readable condition 2 2 Personnel qualification and training The operation maintenance and inspection personnel must have the necessary qualification for the work to be carried out Functional and technical responsibilities and supervision of the operating personnel must be clearly regulated by the Operator Where the personnel does not have the necessary skills and knowledge they must be trained and instructed e g DVS basic welder training in extrusion welding A detailed instruction into hand extruder operation will be provided by the manufacturer supplier on request Furthermore the Operator has to make sure that the contents of the operating instructions is fully understood by the personnel 2 3 Risks resulting from non observance of the safety instructions Failur
28. ied personnel shall be assigned to the operation of the hand extruder 5 2 Preparation Place hand extruder and powerbox on a firm support and secure it against tilting over as shown below Mount hot air hood 128 on the heating cartridge 120 of the hand extruder E el NY Position handle Loosen handle 55 and bring it to ideal working position by pushing it back and forth The handles of MA 40 and ME 40 hand extruders can be swivelled to the right or left as appropriate for use by right handed and left handed persons see sectional drawings on pages 17 22 and 25 Only for ME 40 hand extruder with external air supply Connect hand extruder to external air supply minimum hose diameter of 72 for connection to hand extruder 21 2 minimum air rate 300 l min at 0 4 bar CAUTION The supply air must be clean dry and free from oil and water Do not connect external air supply to the MA 40 hand extruder with integrated air supply ME 40 MA 40 Edition 09 2002 Rev 01 Seite 11 36 Hand Extruder ME 40 MA 40 e Mount welding shoe 5 3 Starting the hand extruder Select the welding shoe required for the specific weld geometry or machine a AN Observe chapter Safety welding shoe blank to the required geometry Observe regulation DVS 2207 Hart A for machining welding shoe blanks Mo
29. me for weld material too short Allow the hand extruder to heat up Heating cartridge defective 13 Air supply not constant With external air supply Check air supply With integrated air supply 1 14 Incorrect rated voltage Rated voltage permissible voltage Check mains voltage Rated voltage permissible voltage Check mains voltage 1 Extension cable heats up Unroll the cable reel Check cable cross section see chapter Safety Extruder nozzle blocked with foreign matter Clean extruder AN Extruder nozzle left hand thread Defect in the drive unit M Controller programming incorrect Welding rod feed Remove welding rod AN Observe the instructions under chapter Maintenance Observe the instructions for extruder operation 21 _ Powerbox fault J 0 9 000 22H tn 23 No mains voltage Check voltage supply 24 Heating switched off Operdeswih i24 Input error Check inputs for incorrect wiring cable discontinuity s err at controller input type and short circuits First switch voltage off and then on If the display 111 at controller does not change the unit needs to be repaired If the display is correct an external interference affecting the controller may be the cause Check for external interferences 1 Consult MUNSCH Kunststoff Schwei technik GmbH 2 Only MA 40 3 Only ME 40 ME 40 MA 40 Edition 09 2002 Rev
30. n 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH Welding material and preheating air temperatures are controlled separately The setpoints and actual values are displayed concurrently Istwert actual value Istwert actual value Sollwert setpoint N Sollwert setpoint N N d N N Yop N FES A if A Al A 7 QUT Massetemperatur melt Lufttemperatur air N 7 X AN an aus er LP J uu On off nr 5 For the drive to be released for starting the weld material and preheating air temperatures must be higher than the respective start up temperatures The temperature controlled start interlock prevents drive starting if there is still unmolten weld material in the extruder thus forestalling damage to the unit As the output rate is variable weld thickness and preheating time can be matched with each other 5 Startup and Shutoff 5 1 General In addition to the operating instructions and the national and local accident prevention regulations applicable at the place of use the acknowledged technical rules for safe and proper working practices must be observed Any working practices posing a safety risk are prohibited Before beginning the startup shutoff procedure the chapter Safety should be carefully read Only trained and qualif
31. re metal parts must not come into contact with other items during the work or breaks e g cooling gt 4 x rated output of hand extruder e Make sure that the hand extruder does not come into contact with water as this may cause a Wy hazard to persons damage to the unit or a short A 5 A gt circuit e CAUTION Never operate the hand extruder without air supply risk of equipment damage When using external air supply make sure that the air supply line is adequately dimensioned e CAUTION The air supplied must be clean dry and free from oil and water IN D02 0001 Contact of combustible components with hot bare metal parts poses a fire risk Do not use synthetic gloves ME 40 MA 40 Edition 09 2002 Rev 01 Seite 7 36 Hand Extruder ME 40 MA 40 Do not direct the hot air jet of the hand extruders toward living beings or temperature sensitive items oafety distance 2 m radius e eo m a m 9 it 002 0002 Use suitable personal protection for overhead work e g hard hat goggles gloves protective clothes to guard against falling items During work breaks and after completion of the work place the hand extruder on the rests included in the supply CAUTION The hot air hood must be re mounted Make sure that the hand extruder is firmly positioned Place hand extruder in a dry location After finishing work cool the hand extruder to
32. red to read the operating instructions Such work includes e operation e maintenance maintenance inspection repair e transport The hand extruder shall only be installed operated and maintained by trained personnel In addition to the operating instructions and the national and local accident prevention regulations applicable at the place of use the acknowledged technical rules for safe and proper working practices must be observed These operating instructions provide basic information to be observed for operation and maintenance For this reason it is imperative that they be read by the specialist personnel operators prior to placing the hand extruder in service and that they are permanently available at the place of use Apart from the general safety instructions under chapter Safety also the special safety instructions given under the respective sub sections must be adhered to Failure to observe safety instructions may cause hazards to persons and the environment or damage to the hand extruder Moreover non observance of the safety instructions may lead to the forfeiture of any damages Non compliance with the safety instructions may in particular involve the following risks e failure of important hand extruder functions e hazards to persons due to electrical and mechanical impacts including risk of burns e hazards to the environment due to vapors of hazardous substances e risk of fire 2 Saf
33. rom this warranty is damage incurred through 6 1 Purchaser s failure to report a defect pursuant to subsection 3a or to provide an opportunity to remedy the defect immediately upon request 6 2 improper handling or overload operation of the purchased article or 6 3 prior repair maintenance or servicing of the purchased article by a company not authorized by the manufacturer if the Purchaser can be reasonably expected to have known that such company was not authorized 6 4 the installation of parts into the purchased article without having obtained the Manufacturer s prior approval for such parts or the modification of the purchased article in a way not approved by the Manufacturer or 6 5 Purchaser s failure to observe the instructions given in the user s manual accompanying the purchased article e g operation maintenance and care or 6 6 the Purchaser having removed the serial number or made it illegible 7 Natural wear and tear shall be expressly excluded from the warranty 8 Accidents force majeure or other circumstances beyond the control of the Manufacturer in particular damage caused by lightning overvoltage water fire etc shall be excluded from the warranty 9 All rights under this warranty shall become null and void on expiry of the warranty term pursuant to Section 1 For claims asserted within the warranty term but not settled by its expiry the warranty shall remain effective until the respective defect
34. t and a function test must be carried out e Ensure the safe and environment friendly disposal of utilities auxiliaries and replaced parts e Re mount and or re activate all safety and protection devices immediately on completion of the work 2 Unauthorised modifications and spare parts Modifications or changes to the unit are only permitted after consultation with the manufacturer In the interest of safety only original spare parts and accessories authorised by the manufacturer should be used The use of components other than the original parts may invalidate the liability for any resulting damage Page 8 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH LJ N SS C Si Plastic Welding Technology 3 Transport and Storage 3 2 Storage 3 1 Transport e Store the hand extruder in a dry and frost free place e Protect the hand extruder from unauthorised access e Special preservation is not required e A Before transport or storage the hand extruder must have cooled down to safe to touch temperature 3 3 Return to MUNSCH N should it become necessary to return the hand The hand extruder may only be held and touched on the handles provided for this purpose extruder E MUNSCH Kunststoff Bare metal parts including the hot air hood must Schwei technik GmbH always use the original not be touched either with or without gloves packaging before having made sure that they are sa
35. torque monitor which prevents hand extruder starting as long as the operating temperature is not attained or the extrudate has not molten down For temperature values see page 15 Temperatures for 40 40 5 4 Welding with the hand extruder Observe chapter Safety and data sheet General Welding is to be carried out in accordance with the regulations of the German Association for Welding Technology Deutscher Verband f r Schwei technik DVS The material to be welded and the welding rod must be dry and clean 5 4 1 Introducing the welding rod CAUTION The hand extruder is provided with two bores for introducing the welding rod Make sure to introduce only one welding rod at a time either a 4 mm rod or a 5 mm rod Never introduce two rods at a time into the rod bore Im 5 4 2 Replacement and ageing of welding rod e Ifthe welding rod is replaced make sure that no old rod is still present in the hand extruder e Forthis purpose operate the preheated hand extruder with the new rod until clean new material discharges ME 40 MA 40 Edition 09 2002 Rev 01 Seite 13 36 Hand Extruder ME 40 MA 40 e The DVS regulations also recommend this measure for hand extruders which have been out of service for prolonged periods while being filled with welding rod e AN Ensure safe and environment friendly disposal of any wastes generated 5 4 3 Welding direction rat
36. unt welding shoe on the hand extruder in the position required for welding Observe welding direction Tighten set screw 25 e Mount preheating nozzle on extruder Select the preheating nozzle 4 for the specific weld type and mount it on S the extruder Observe spacing A 5 mm Tighten preheating nozzle by means of set screw 25 1 25 1 D47 0003 Table Preheating nozzle e AT MA N nn H e S C ee gt Make sure that the preheating nozzle provides intense and uniform heating melting of the base material over the entire weld width at minimum hot air temperature CAUTION The hand extruder must not be operated without air supply Failure to observe this may cause severe damage to the unit CAUTION Before plugging in the mains connector check that the drive is not set to continuous operation CAUTION The hot air hood 128 must be mounted on the heating cartridge 120 of the hand extruder NN CAUTION Start external air supply for hand extruder ME 40 CAUTION Connect the cable between the Powerbox and the hand extruder CAUTION Plug in mains connector CAUTION With the MA 40 hand extruder with integrated air supply the blower must start automatically Page 12 36 Edition 09 2002 Rev 01 MUNSCH
37. ure above the preset range 2 3 18 19 Temperature display on the controller 5 err 27 Temperature display on the controller e 111 Temperature display on the controller Temperature display on the controller 2222 Variations from setpoint temperature 7 2 Fault diagnosis 2 3 4 5 18 22 24 28 29 3 13 19 ld Possible causes Remedies Welding rod diameter smaller or too small If necessary use a larger welding rod diameter 2 Temperatur sensor defective 3 Temperatur controller defective 4 Air throughput too high Reduce air supply to the specified rate 5 Cable connections defective Check cable connections 6 External air supply not connected Connect external air supply External air supply out of function Switch on external air supply Check the external air supply system for malfunctions using the separate manual or have it checked Hot air temperature below the start release Allow the hand extruder to heat up temperature Air flow too high lower air flow 1 Consult MUNSCH Kunststoff Schwei technik GmbH 2 Only MA 40 3 Only ME 40 Page 30 36 Edition 09 2002 Rev 01 MUNSCH Kunststoff Schwei technik GmbH IN LI IN I Plastic Welding Technology Welding deposit temperature below the start Allow the hand extruder to heat up release temperature Preheating time for hot air too short Allow the hand extruder to heat up Preheating ti
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