Dohle ExOn5 User manual

Bedienungsanleitung
Operating Instructions
ExOn5, DX309
Dohle Extrusionstechnik GmbH
Eitorfer Strasse 1
D – 53809 Ruppichteroth
.dohle-extruder.de

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 18
We retain all copyrights of all descriptions, dra ings and schedules contained in these
operating instructions hich may not be reproduced nor be made accessible by third parties
or by competitors, neither in hole nor in part, unless e have expressly consented thereto.
Before start-up these operating instructions must be examined carefully because e ill not
assume any liability for any failures resulting from improper use. No arranty claims ill be
accepted if the hand-held elding and extruding machine has been modified unless this has
been done in consultation ith the manufacturer/ supplier.
The appliance is not to be used by persons (including children) ith reduced physical,
sensory or mental capabilities, or lack of experience and kno ledge, unless they have
been given supervision or instruction.
Children must be supervised not to play ith the appliance.
The extruder shall be used for extrusion eld orks only !
These operating instructions should al ays be accessible by the operator.
For after-sales service and orders please contact:
DOHLE Extrusionstechnik GmbH
Eitorfer Strasse 1
D-53809 Ruppichteroth
Telephone: [phone] – 902960
Telefax: (+49) 02295 – 902961
E-Mail: [e-mail]
.dohle-extruder.de
english
Content
1. Description of Type 19
2. Safety 19
3. Start-up 21
4. Error tracing 24
5. Dra ings, Informations 25

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 19
1. Type
Article-no. / Type of machine : DX309 ExOn5
Machine no. : .........
Required voltage : 400 V / 50 – 60 Hz
2. Safety
Pursuant to section 55 of VDE 0 100 (Regulations of the Association of German
Electrotechnical Engineers), the extruder must be operated using a protective s itch or an
isolation transformer. Al ays keep extruder dry!
Operating hand-held elding and extruding machines is subject to applicable national
regulations. Observe applicable regulations for the prevention of accidents as ell as
technical rules for safe and professional operation.
Directive 92/ 57/ EWG dated June 24, 1992, shall be applicable by analogy.
Utilisation:
Hand-held elding and extruding machines are manufactured according to the latest state of
the art and in compliance ith safety requirements.
Any improper use may result in dangers for the operator or third parties or may adversely
affect machines and assets.
Only use hand-held elding and extruding machines if in technically perfect condition and for
the purposes for hich they are intended hile observing the operating instructions.
The manufacturer / supplier ill not accept any liability for any failure to comply ith the
above or for damages resulting there from.
Any utilisation of the hand-held elding and extruding machine for other purposes than those
for hich it is intended is subject to the consent of the manufacturer / supplier.
Work on electrical parts of the hand-held elding and extruding machines may only be
performed by an electrical engineer in compliance ith electro-technical rules.
Special risks:
All hand-held elding and extruding machines may only be held and operated using the
handles provided for this purpose.
A risk of burning exists on all uncovered metal parts. Avoid contact ith these parts
because they may achieve temperatures of up to 350 °C.
Caution: Heat can reach combustible materials!
Safety area:
The hot air stream of the hand-held elding and extruding machine may not be directed to
temperature-sensitive objects or living things. Ensure that a safety distance of 2m is
observed in all directions.
Don’t concentrate the heat stream long time on the same area.

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 20
Operation:
Never use hand-held elding and extruding machines ithout air supply.
In case of external air supply ensure that the feed line is of sufficient size.
The pressurised air that is supplied must be free of oil and ater.
Overhead ork:
When orking overhead al ays ear appropriate safety devices (such as helmet,
savety glasses etc.).
Safety:
Check for correct nominal voltage before connecting the hand-held elding and extruding
machine to the mains voltage.
Mains voltage must be identical to the nominal voltage sho n on the type plate of the hand-
held elding and extruding machine.
Pursuant to sec. 55 of VDE 0 100 the hand-held elding and extruding machine must be
operated using a protective s itch or an isolation transformer.
Extension cords:
When using extension cords the minimum diameter of cables must be observed.
Length up to 18 m: diameter 2.5 mm²
Length up to 50 m: diameter 4.0 mm²
Extension cords must be approved and marked for their place of utilisation.
Stop operating the hand-held elding and extruding machine if:
- connecting line or plug have been damaged
- safety installations have been damaged
- foreign objects or liquids have entered the hand-held elding and extruding machine
-changes occur in the operating state
Never spray ater on hand-held elding and extruding machines
(risk of short circuit)
Never use hand-held elding and extruding machines in hazardous or inflammable
areas.

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 21
3. Start-up
General:
Observe the notes on safety contained in these operating instructions. In addition, the
regulations on the prevention of accidents and the national regulations shall apply.
Assembling the hand-held elding and extruding machine
When dispatched, our hand-held elding and extruding machines are almost completely
assembled.
What remains to be done is to scre the enclosed handle to the machine.
For machines ith external air supply the air supply hose must be connected.
Ensure sufficient supply ith air hich is free of oil and ater (min. 300 l/min).
We recommend our air compressor, item no. DX 011.
Weld shoe
The machine is supplied ith t o eld shoes blank hich can be machined to suit your
requirements.
Note: please observe guideline DVS 2207 part 4.
If you indicate your required form of seam and thickness of plates e ill supply t o eld
shoes machined ready for use.
Start-up of hand-held elding extruder
Observe the section concerning safety of these operating instructions.
Hand-held elding and extruding machines may not be used ithout air supply.
This ould inevitably result in damages of the extruder.
Before connecting the extruder to the mains supply please check that:
- air supply is connected correctly
- the driving machine has not been put to permanent operation
- no s itch on air supply
-and put plug into socket.
If you give no the po er supply plug to a suitable plug socket (230V, 16A), press that
On - Off s itch on the air heater on position ON.
The machine heats no up.
Make sure by each s itching on of the machine, that the on-off s itch of the drive
engine is s itched off.
After a heating-up time of approx. 15 minutes, start the machine using the elding material
ished by you and examine the air and elding material temperature ith a suitable
temperature measurement. By changing the temperature of the air heater consider the
reaction response time of the system.

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 22
Vie – controller front – steering box
standard optional
Display and control elements of the controller front
Controller – desired value setting
All controllers can be changed only in the desired value and are electrnically locked against
rong inputs.
Change the desired value
The controller indicates actual and desired value temperature at the same time. To change
the desired value temperature proceed as follo s:
Desired value temperatur
Up ard - key
Do n ard
-
key
By every press of this key, the value
becomes smaller, hich is indicated
on the desired value display. If this
key is kept constantly pressed, then
the value is sequentially becomes
smaller.
Up ard
-
key
By every press of this key, the
value increases, hich is indicated
on the desired value display. If this
key is kept constantly pressed,
then the value sequentially
becomes higher.
Actual value temperature
tettempevalue
temperatur
Do n ard - key
AL (Alarm)
Shines if the alarm
exit is on
Temperatur
e unit
Do not press these keys.
D - 2381 controller extruder ExOn5 mass
D - 2377 temperature controller ExOn2-6 air
D - 2384 s itch heater ExOn2-6
D - 2383 poti ExOn2-6
D - 2383 poti ExOn2-6
air flo
speed extruder

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 23
Change of the elding shoe
In order to be sure that no more old elding rod is in the hand elding extrusion, heat up the
machine on operating temperature, remove the elding shoe and change the nozzle (note:
left hand thread!).
Changing the elding filler
Heat up the hand-held elding and extruding machine until operating temperature is
reached to ensure that no elding filler is present in the machine, remove the eld
shoe and exchange the die (caution, left-handed thread) by a ne one or by a die
used ith the material to be applied no .
Note: ith ork on heated machine burn danger.
When the nozzle is changed drive for approx. 1 min. the ne elding rod in the hand elding
extrusion.
Interruption of the elding
Do not leave the hand elding extruder unsupervised.
The air supply must remain maintained
Caution: When processing PVC or PVDF, hand-held elding and extruding machines
may not be stopped for more than 3 min.
In such a case or if elding operations are completed a cleaning run must be performed
on the machine for about 2 min. using PE or PP elding filler.
S itch off the hand elding extruder
Bring the potentiometer of the air heater in position 0 and pull after ca.2 minutes
the po er supply plug.
Note: Even after 15 minutes still exists burn danger on bright metal parts.
No ater or other materials for accelerating the cooling procedure must be used. .
Maintenance
Before maintenance ork on the equipment, pull po er supply plug!
Maintenance ork may be accomplished only by electrical specialists.
Consider the security chapter!
After approximately 500 operation hours the hand elding extruder, including the drive unit
must be cleaned, greased and controlled. These ork may be implemented only by electrical
specialists.
Drive
The carbon brushes conductors of the drive must be examined approx. every 200 operation
hours and rene ed if necessary.
Deep groove ball thrust bearing /barrel extruder
The deep groove thrust bearing and the barrel extruder should be cleaned approx. every
200 operation hours and again be greased
Note: Only high temperature grease can be used. Our art. no.: D-0581

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 24
4. Error tracing
Malfunctioning Error– No.
Driving motor does not start 01,02,04,05,06,07,08,09,10,11,12
Driving motor s itches off 03,04,05,06,07,08,09,10
Extruder remains cold 04,05,06,07,08,09,15,17
Hot air remains cold 05,07,08,09,12
Hot air temperature is under 11,13
desired value
Extrusion temperature is under 11
desired value
Extruder does not deliver extruded 11
material from the die
Display does not light up 01
Display sho s: S . e r r 15
Display not constant 17
Display sho s rong direction of action 18
Error-No. possible cause Elimination of error
01 No po er supply Provide po er supply
02 Incorrect mains voltage Have checked by skilled technician
03 Extension cord becomes hot Check cable diameter
Run out cable completely from reel
04 Thermoelement for mass defective Exchange thermoelement
05 Thermoelement for air defective Exchange thermoelement
06 Temperature control unit for mass
defective
Exchange temperature control unit
07 Temperature control unit for air defective Exchange temperature control unit
08 On/Off s itch for heating units in OFF
position
Put s itch to ON position
09 Defect on cable connections Have checked by skilled technician
10 Carbon brushes of drive motor orn Replace by ne carbon brushes
11 Pre-heating time too short Heat up extruder
12 External air supply not connected Connect external air supply
13
Air flo too high hen using external air
supply
Reduce to prescribed quantity
15 Breakage of monitoring thermoelement Replace thermoelement
16 Unsuccessful attempt to change a
blocked parameter
Blockage can only be removed by a
skilled technician
17 Thermoelement failure or loose
connections
Check thermoelement
Check connections
18 Sensor incorrectly connected,
+ and – mistaken
Check connections

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 25
5 Dra ings, Informations
DX309 ExOn5
D - 0012
D - 1516
D - 1664
D - 0163
D - 0363
D - 0350
D - 1084 D - 0559
D - 2377 D - 2381 D - 2384 D - 2383
D - 0402.2
D - 1646
D - 1858
D - 0233
D - 0710
D - 1811
D - 2077
D - 0647
D - 0160
D - 1754 D - 1807
D-2402
D - 1788
D - 1861
D - 2370
D - 0250
D - 0378

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 26
article-no description qty
6600646 angled hose scre fitting 1
D - 0012 feather key 1
D - 0160 scre M6x10 2
D - 0163 deep groove ball thrust bearing 1
D - 0233 orm type 5000 1
D - 0250 Extension burner pipe 30mm 1
D - 0288 scre 2,2x6,5 4
D - 0350 thread nipple 1
D - 0363 hinge pin for hose clamp 1
D - 0378 die 5000 1
D - 0402.2 holder BSM 282 Pos2 1
D - 0559 cylinder draft Weka 1
D - 0647 holder-control box 1
D - 0710 scre M6x65 DIN912 4
D - 0864 scre 2.9x6.5 DIN 7981 4
D - 1084 Handle M10 1
D - 1085 ring handle 5002 1
D - 1516 strip heater ExOn5-6 1
D - 1646 cooling rips ExOn2-6 1
D - 1650 gasket heatsink ExOn2-6 1
D - 1664 Eron ExOn2-6 1
D - 1754 mainboard ExOn2-6 1
D - 1788 burner pipe ExOn5 1
D - 1807 line filter ExOn5-6 1
D - 1811 control box ExOn2+3 1
D - 1834 front paneel ExOn2+3 1
D - 1858 cylinder ExOn5 complete 1
D - 1861 thermoelement extruder ExOn5-6 1
D - 2050 scre ed cable buckelproofed PG11 1
D - 2077 Drive unit Weka 1
D - 2134 idening PG9-PG11 1
D - 2290 supply cable 5x1,5 1
D - 2291 CEE plug 5pol 16A 1
D - 2322 scre ed cable M16x1,5 1
D - 2370 sealing ring CU 1
D - 2377 temperature controller ExOn2-6 air 1
D - 2381 controller extruder ExOn5 mass 1
D - 2383 poti ExOn2-6 1
D - 2384 s itch heater ExOn2-6 1
D - 2402 inductor Exon5 1

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 27
Eron ExOn2-6, Art-Nr: D - 1664
5101270
6600613
66006366600645
6600601
5113268
66006145101760
6600612
D - 2279
6600647
6600648 66006466600644
6600606
6600622
6600596 D - 2399
6600637
6100284
6600639
6600622
6600607

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 28
article-no description qty
5101270 gasket 70x48x4 1
5101760 mica tube 47,6x95 1
5113268 heating element 230V/2200W 1
6100284 countersunk scre M4x12 TX 3
6100287 hexagon nut M5 1
6113695 temperatur limit s itch 135°C 1
6600596 thermoelement 1
6600601 air filter 1
6600606 motor 230V SL 1
6600607 carbon brush 2
6600612 rubber ring 1
6600613 turbine housing lo er part 1
6600614 stripper 1
6600616 countersunk scre M3x10 TX 4
6600622 fillister head scre M4x10 TX 6
6600636 turbine 1
6600637 turbine 1
6600639 handle 1
6600644 connecting piece for cable sleeve 1
6600645 turbine housing upper part ith hole1/4" 1
6600646 angled hose scre fitting 1
6600647 cable sleeve 290mm 1
6600648 hose scre fitting straight 1
D - 2279 plastic nut M16x1,5 2
D - 2399 inductor Eron 1

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 29
Spare Parts Drive Unit

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 30
p
os.
art.
-
n
o
.
d
escription
q
ty.
1 DW014 drive housing 1
2 DW017 gap cap 1
3 DW018 bearing cap ith cover 1
5 DW019 s itch handle 1
6 DW020 isolating cap 1
8 D-2167 anchor cmpl. ith. blo er a. bearing 1
10 DW022 magnet housing compl. 1
11 DW023 sealing bush 1
13 DW024 electronic housing 1
14 DW025 bolt Isolating cap 2
15 DW026 brush arch compl. 1
16 DW027 arial coductor disc 1
25 D-2078 carbon brush 2
28 DW007 deep groove ball bearing 1
29 DW029 deep groove ball bearing 1
30 DW030 spacer disc 1
32 DW006 o-ring RDR26x2,5 1
34 DW002 sealing bush ith shaft seal 1
37 DW032 head cap scre M5x35 4
38 DW033 head cap scre M5x20 4
39 DW034 cylindersre 4x100 2
40 DW035 cylindersre M3x5 2
42 DW036 flat headed scre M4x6 1
48 DW039 hex nut M4 2
52 DW040 lock asher SM5 4
54 DW041 spring disc A4 3
55 DW042 asher 4,3 1
26 DW043 asher 3,2 2
59 DW044 closing plate 1
60 DW045 interferenc suppression capacitor 1
61 DW046 po er cord 1
65 DW049 main s itch 1
70 DW050 level tube 1
71 DW051 box level 1
73 DW008 blo er 1
100 DW052 gear case 1
106 DW067 shaft 1
107 DW053 through-drive countershaft 1
108 DW054 through-drive heel 1
109 DW055 arbor heel 1
115 DW056 needle bearing 1
116 DW057 axial needle bearing AXK/AS 0515 1
119 DW058 deep groove ball bearing 6005Z 1
120 DW059 deep groove ball bearing 6005 1
121 DW060 needle bush HK1010 1
123 DW003 o-ring RDR78x2 1
127 DW001 shaft seal AD24x40x7 1
140 DW061 keyA5x5x12 1
142 DW062 cylindrical pin 4m6x10 1
145 DW063 adjusting asher PS10x16x1 1
149 DW012 retaining ring SW18 1
155 DW064 Ihead cap scre M5x70 1
156 DW065 head cap scre M5x100 3
160 DW066 disc SM5 4

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 31

Operating Instructions
DOHLE Hand Welding Extruder ExOn5
DOHLE Extrusionstechnik GmbH 32
Welding Shoes
a
s
s
s
s
X - eld
D-0174
D-0175
D-0177
D-0178
D-0179
D-0180
D-0181
D-0182
5-8
10-12
15
20
25
30
35
40
D-0183
D-0184
D-0185
D-0186
D-0187
D-0188
D-0189
D-0190
D-0191
5-8
10
15
20
25
30
35
40
12
D-0195
D-0196
D-0197
5-8
10-12
15
D-0600
D-0366
D-0337
Ø
20
15
Ø
Ø
D-0192
D-0193
D-0194
D-0599
25
30
35
40
D-0198
D-0199
D-0200
D-0201
D-0202
D-0203
D-0204
10
15
20
25
30
35
40
D-0223
D-0224
D-0225
D-0247
D-0248
D-0598
30 x 30 x 45
35
25
Ø
30 x 40 x 50
30 x 45 x 45
50 x 60 x 80
50 x 70 x 80
a = s x 0,7
s = thickness of material
fillet eld corner eld
V-seam
overlap eld
thickness of material order - no.
elding shoe, round
idth of eld B
elding shoe - unshaped
please require for shoes for special application
size
thickness of material order - no.
thickness of material order - no.
thickness of material order - no.
order - no.
order - no.
order - no.
B