Munsch MEK-32, MAK-32, MEK-36, MAK-48, MEK-48 Operating Instructions Manual
...
MUNSCH Kunststoff-Schweißtechnik GmbH Issue 12.2009/Rev. 02 Page 1/20
Operating Instructions
Type: MEK-32 / MAK-32 Serial No.: ______________
Article No.: ______________
These operating instructions contain important
information to be observed for hand extruder operation
and maintenance.
It is therefore imperative that they be read and their
contents fully understood by the operators before the
hand extruder is placed in service.
Hand Extruder MEK-32 / MAK-32
Page 2/20 Issue 12.2009/Rev. 02 MUNSCH Kunststoff-Schweißtechnik GmbH
Scope of delivery:
Please check that the delivery is complete.
The delivery comprises:
1 hand extruder 1 extruder stand
1 handle
1 welding shoe, machined
3 preheat nozzles
1 hot air hood
Contents
1 GENERAL......................................................................................................................................................................4
2 SAFETY..........................................................................................................................................................................4
2.1 I
DENTIFICATION OF INFORMATION IN THE OPERATING INSTRUCTIONS
.......................................................................5
2.2 P
ERSONNEL QUALIFICATION AND TRAINING
..............................................................................................................5
2.3 R
ISKS RESULTING FROM NON-OBSERVANCE OF THE SAFETY INSTRUCTIONS
..............................................................5
2.4 S
AFE WORKING PRACTICES
........................................................................................................................................5
2.5 S
AFETY INSTRUCTIONS FOR OPERATOR / OPERATING PERSONNEL
.............................................................................5
2.6 S
AFETY INSTRUCTIONS FOR MAINTENANCE, INSPECTION AND MOUNTING
.................................................................7
2.7 U
NAUTHORIZED MODIFICATIONS AND SPARE PARTS
..................................................................................................7
3 TRANSPORT AND STORAGE ...................................................................................................................................8
3.1 T
RANSPORT
...............................................................................................................................................................8
3.2 S
TORAGE
...................................................................................................................................................................8
3.3 R
ETURN TO MUNSCH
.................................................................................................................................................8
4 PRODUCT DESCRIPTION .........................................................................................................................................8
4.1 A
PPLICATION RANGE
.................................................................................................................................................8
4.2 G
ENERAL
...................................................................................................................................................................8
5 STARTUP AND SHUTOFF..........................................................................................................................................9
5.1 G
ENERAL
...................................................................................................................................................................9
5.2 P
REPARATION
............................................................................................................................................................9
5.3 S
TARTING THE HAND EXTRUDER
.............................................................................................................................10
5.4 W
ELDING WITH THE HAND EXTRUDER
.....................................................................................................................11
5.4.1 Introducing the welding rod............................................................................................................................11
5.4.2 Replacement and aging of welding rod...........................................................................................................11
5.4.3 Welding direction / rate ..................................................................................................................................11
5.4.4 Interruption of work........................................................................................................................................11
5.4.5 Shutoff ............................................................................................................................................................12
5.4.6 Transport/Storage............................................................................................................................................12
5.5 S
ET TEMPERATURES ON TEMPERATURE CONTROLLER
.............................................................................................12
5.5.1 Set temperatures..............................................................................................................................................12
6 MAINTENANCE/INSPECTION ...............................................................................................................................14
6.1 M
AINTENANCE/INSPECTION OF
MEK/MAK
HAND EXTRUDER
................................................................................14
6.2 D
ISMANTLING
..........................................................................................................................................................14
6.2.1 Overview of spare parts/attachments ..............................................................................................................14
7 MALFUNCTIONS, CAUSES AND REMEDIES......................................................................................................16
7.1 T
ROUBLE-SHOOTING
................................................................................................................................................16
7.2 F
AULT DIAGNOSIS
....................................................................................................................................................16
8 TECHNICAL DATA ...................................................................................................................................................18
MEK-32 / MAK-32 Issue 12.2009/Rev. 02 Page 3/20
EG-Konformitätserklärung des Herstellers
nach der EG-Maschinenrichtlinie 2006/42/EG Anhang II, Nr. 1 A
EC-Declaration of Conformity by the Manufacturer
as defined by machinery directive 2006/42/EC, Annex II, No. 1 A
MUNSCH Kunststoff-Schweißtechnik GmbH
Im Staudchen
D-56235 Ransbach-Baumbach
Germany
Mr. Johann Dausenau,
Kunststoffschweißtechnik GmbH,
is authorised to compile the technical documentation.
We hereby declare that the hand extruders
Machine type: Hand extruder Hand extruder
Type designation: MEK-32 MAK-32
are in accordance with all relevant provisions of the EC Machinery Directive.
The following harmonised standards (or parts of these standards) were applied:
DIN EN ISO 12100-1: 2004 DIN EN 13732-1: 2008
DIN EN ISO 12100-2: 2004
In addition, the hand extruders are in accordance with the following EC-directives, standards, codes and
regulations:
EU Low-Voltage Directive 73/23/EC EU EMC Directive 89/336/EC
EN 60204-1 (VDE 0113 Part 1): 2007 DIN EN 55014-1: 2007
EN 61029-1 (VDE 0740 Part 500): 2003 DIN EN 55014-2: 2009
VDE 0701 Part 1: 2008
VDE 0702 Part 1: 2003
This industrial tool complies with the aforesaid standards insofar as it is used at the contractually agreed
conditions. The operator is responsible for this.
In the event of any modifications to the machine/unit or use not as intended, this declaration becomes invalid
unless the manufacturer’s prior written approval has expressly been given.
Ransbach-Baumbach, 29.12.2009 Dipl.-Ing. Stefan Munsch
Managing Director
Hand Extruder MEK-32 / MAK-32
Page 4/20 Issue 12.2009/Rev. 02 MUNSCH Kunststoff-Schweißtechnik GmbH
1 General
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.
These 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.
These operating instructions must be observed by all
persons working with/on the hand extruder. Such
work includes, for instance:
• operation,
• maintenance, inspection and repair
• transport.
The hand extruder may only be mounted, 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/Operator
prior to placing the hand extruder in service and that
they always be available at the place of use.
Apart from the general safety instructions under
section “Safety“, also the special safety instructions
given under the respective sub-sections must be
adhered to.
Non-observance of the safety instructions
may cause hazards to persons and the environment
or damage to the hand extruder.
Moreover, failure to observe the safety instructions
may lead to the forfeiture of any damages.
Non-observance of the safety instructions may in
particular involve the following risks:
• failure of important hand extruder functions,
• hazards to persons due to electrical and
mechanical impacts including risk of burns,
• hazards to the environment due to vapour-phase
hazardous substances,
• risk of fire.
2 Safety
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/Operator
prior to placing the hand extruder in service and that
they always be available at the place of use.
Safe operation of the hand extruder presupposes
that the instructions under section 1 – General – of
these operating instructions are complied with. In no
case must the limit values indicated be violated.
Intact and unaltered hand extruders conform to the
applicable codes and standards and meet all
regulatory limit values regarding EMC
(electromagnetic discharges and interference
immunity). For the country-specific limit values to be
observed, the Operator should consult the local
electric utility. Nevertheless, the hand extruders emit
electromagnetic fields within the acceptable limits.
Electromagnetic fields may interfere with the
operation of vital electronic devices (e.g. cardiac
pacemakers). Persons wearing a cardiac pacemaker
should therefore 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
must be observed.
Apart from the general safety instructions under
section “Safety“, also the special safety instructions
given under the respective sub-sections must be
adhered to.
Any working practices posing a safety risk are
prohibited.
MEK-32 / MAK-32 Issue 12.2009/Rev. 02 Page 5/20
2.3 Risks resulting from non-observance of the
safety instructions
Non-observance of the safety instructions may cause
hazards to persons and the environment or damage
to the hand extruder. Moreover, failure to observe
the safety instructions may lead to the forfeiture of
any damages.
Non-observance of the safety instructions may in
particular involve the following risks:
• failure of important hand extruder functions,
• hazards to persons due to electrical and
mechanical impacts including risk of burns,
• hazards to the environment due to vapour-phase
hazardous substances,
• 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 instructions, operating and safety procedures
issued by the Operator must be followed.
2.5 Safety instructions for Operator / operating
personnel
• Before placing the hand extruder in service,
check the mains voltage and frequency against
the data indicated on the type tag. The allowable
tolerances are ± 5 % for voltage and/or ±2 % for
frequency.
• According to VDE 0100 §55, the hand extruder
must be operated via a residual current-operated
circuit breaker or an isolating transformer.
• CAUTION During hand extruder operation (under
load), a voltage of not less than 230 V1) must be
available at the connector of the hand extruder.
• When using an extension cable, make sure to
observe the minimum conductor cross-section.
Use extension cables with protective conductor
only.
Length
[m]
Minimum cross-section
[mm²]
up to 19 4.0 1)
20-50 6.0 1)
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 legible
state.
2.2 Personnel qualification and training
The operating, maintenance and inspection
personnel must possess appropriate qualification for
the work to be performed. Functional and technical
responsibilities and supervision of the operating
personnel must be clearly regulated by the Operator.
Where the personnel do not have the necessary
skills and knowledge they must be trained and
instructed (e.g. a 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
operating personnel.
1) for 230 V AC
Hand Extruder MEK-32 / MAK-32
Page 6/20 Issue 12.2009/Rev. 02 MUNSCH Kunststoff-Schweißtechnik GmbH
• Extension cables must be certified for the specific
service conditions (e.g. outdoor service) and
identified accordingly.
Always handle the connecting cable with care.
- Do not kink the connecting cable.
- Do not place any objects on the cable.
- Do not jam or squeeze the connecting cable,
nor pull it over sharp edges.
- Protect the connecting cable from moisture.
• Do not touch the mains connector or
connecting cable with wet hands. Hold the cable
always at the connector when plugging or
unplugging it.
• CAUTION Power generator sets used for power
supply must be designed for the following rated
output:
≥ 4 x rated output of hand extruder
• Never allow the hand extruder to come into
contact with water: Hazard to persons and
equipment, short-circuit risk.
• CAUTION Never operate the hand extruder
without air supply; risk of hand extruder
damage.
When using an external air source, make sure
that the air supply line is adequately
dimensioned.
• CAUTION The supply air must be clean, dry and
free from oil and water.
• The hand extruder must not be used in
explosion hazard areas or flammable
atmospheres.
Make sure that the hand extruder is firmly
positioned during the extrusion welding job.
The connecting cable, welding rod and hose for
external air supply, if applicable, must be freely
movable and must not obstruct the operator or
third parties in their work.
• Hold and touch the hand extruder only on
the handles provided for this purpose.
- Do not touch bare metal parts (including hot
air hood) either with or without gloves. These
parts reach temperatures of up to 350 °C.
- Attachments may be damaged or impaired
in their function if subjected to the full weight
of the hand extruder.
- Bare metal parts must not come into contact
with other items during the work or work
breaks (e.g. cooling).
FIG. D02-0001
• Contact of combustible components
with hot bare metal parts poses a risk of fire!
Do not use synthetic gloves!
D02-0001
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