Dohle ExOn3A User manual

Bedienungsanleitung
Operating Instructions
ExOn3A, DX306
ExOn3A-5, DX314
Dohle Extrusionstechnik GmbH
Eitorfer Strasse 1
D – 53809 Ruppichteroth
.dohle-extruder.de

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 16
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) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have
been given supervision or instruction.
hildren must be supervised not to play with the appliance.
The extruder shall be used for extrusion weld works only !
These operating instructions should always 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
ontent
1. Description of Type 16
2. Safety 16
3. Start-up 19
4. Dra ings, Informations 21

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 17
1. Type
Article-no. / Type of machine : DX306 ExOn3A / DX314 ExOn3A-5
Machine no. : .........
Required voltage : 230 V / 50 – 60 Hz
Heating unit : 3500W/15A
Processing of : PE, PP
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.
aution: 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 ExOn3A
DOHLE Extrusionstechnik GmbH 18
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 water.
Overhead work:
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 welding 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 water on hand-held welding and extruding machines
(risk of short circuit)
Never use hand-held welding and extruding machines in hazardous or inflammable
areas.
To park the tool:
To save the stand, click the machine base out and put the
tool on the three points (machine base – handle drive unit –
pivoted handle).
Make sure that the machine base to the pivoted handle is in
angle of 90°.
9
0
°
c
a
.

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 19
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 welding and extruding machine
Our hand extruders are largely fully assembled ready for accommodated.
Weld shoe
The machine is supplied ith one eld shoe 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 one eld
shoe machined ready for use.
Start-up of hand-held welding extruder
Observe the Safety chapter of this manual.
Before plugging in the po er cord, please check that
- The heating is s itched off at the air heater
- The engine is not set for continuous adjustment
- Plug in the po er cord
Enter the po er cord into an AC outlet (230V, 16A), use only easily accessible electrical
outlets, you represent no the on - off
the heater s itch on the ON position.
The machine heats no on to the last selected setpoint temperature.
To change the temperature, they change the setting of
Potentiometer on the heat gun.
The hand extruders exon 3A has a bi-metal cold start protection, the
Device only partially protects against major damage. Al ays observe the longer
Heat-up times and minimum temperatures of the materials to be processed.
Incorrect operation has a fraction of the scre or the transmission of
Follo .
Warranty claims that are due to incorrect operation cannot be claimed
aution: Observe minimal heat time of 20min.
Let the appliance unattended while it is operating.

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 20
hange of the welding 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!).
hanging the welding 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: with work 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 welding
Do not leave the hand elding extruder unsupervised.
The air supply must remain maintained
Switch off the hand welding 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 water 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.
onsider the security chapter!
After approximately 300 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 120 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
120 operation hours and again be greased. (Note: Only high temperature grease can be
used.)

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 21
4. Drawings, Informations
DX306 ExOn3A, DX314 ExOn3A-5
D - 1742
D - 1630
D - 1748
D - 1749
D - 1769
D - 1793
D - 2014
D - 1729
D - 1768
D - 1636 D - 0042
D - 1320
D - 1728
D - 0688 D - 0690
D - 0567
D - 1319
D - 1512
D - 1744
D - 1513
D - 0854
D - 1771 D - 1771
DV 131
D - 1772
DB 044
D - 2063
D - 1630
D - 1778
D - 0632
D - 0864

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 22
article-no description qty
D - 0012 feather key 1
D - 0042 air die multi fix 32mm 1
D - 0632 scre M5x65 4
D - 0680 compression spring handle 1
D - 0687 link 1
D - 0688 link joint 1502-3002 1
D - 0690 ball button 1502 - 6002 1
D - 0726 ball 1
D - 0727 press sleeve 3x16 1
D - 0845 scre M5x6 2
D - 0854 handle 1
D - 0864 scre 2.9x6.5 DIN 7981 4
D - 1302 Potentiometer scale Micro 1
D - 1319 temperature s itch T10B 1
D - 1320 Eron Extruder ExOn3A 1
D - 1512 orm ExOn3 1
D - 1513 orm ExOn3-5mm 1
D - 1630 control box ExOn3A 1
D - 1636 die ExOn3A 1
D - 1728 angle scre ed cable M16x1,5 1
D - 1729 phase angle control 1
D - 1742 cylinder ExOn3A 4mm 1
D - 1744 cylinder ExOn3A 5mm 1
D - 1748 flange ExOn2-4 1
D - 1749 indentation1 ExOn2-4 1
D - 1768 burner pipe ExOn3A 1
D - 1769 deep groove ball bearing 61904 2Z ISB 1
D - 1771 scre M5x16 8
D - 1772 scre M4x6 T20 DIN7985 2
D - 1778 axis ExOn2-6 1
D - 1793 indentation2 ExOn2A+3A 1
D - 2014 potenziometer 100k 1
D - 2050 scre ed cable buckelproofed PG11 1
D - 2063 main cable 8m 1
DB 044 drive unit BSM 275, 230V, 1400W 1
DV 131 scre M4x8 T20 DIN7985 1

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 23
D-1320 Eron 230V/2300W
5101270 6600613
66006366600638
5113268
6600614
6600637 6600602
6600606
6100284
66006166113695
66006126101760
6600611
6100268 6100444
6100263
6600608
6106186
6101242
6100287
6600616
6600622
6600609

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 24
article-No description qty
5101270 gasket 70x48x4 1
5113268 heating element 230V/2200W 1
6100263 potentiometer knob red 1
6100268 strain relief 1
6100284 countersunk scre M4x12 TX 3
6100287 hexagon nut M5 1
6100444 cord guard 9,6x75 1
6101242 connecting shackle 1
6101760 mica tube 47,6x95 1
6106186 rocker s itch 1
6113695 temperatur limit s itch 135°C 1
6600601 air filter 1
6600602 handle 1
6600606 motor 230V SL 1
6600607 carbon brush 2
6600608 potenziometer 10KOhm 1
6600609 electronic circuit board 230V 1
6600610 triac 25A/800V 2
6600611 PT fillister head scre M3x8 TX 8
6600612 rubber ring 1
6600613 turbine housing lo er part 1
6600614 stripper 1
6600615 phototransistor 1
6600616 countersunk scre M3x10 TX 4
6600622 fillister head scre M4x10 TX 2
6600636 turbine 1
6600637 turbine 1
6600638 turbine housing upper part 1

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 25
Spare Parts Drive Unit
DB044

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 26
Art.No Qty Description
DB047
1
Gear BSM 275
DB049
1
Id
ler 8Z
DB050
1
Gearwheel 26
Z
DB006
1
Flat Gasket
DB007
2
ylinder Pin 4m6, 6x16 DIN7
DB0
43
1
Engine Flap
DB0
51
1
Ball Bearing 6201 2
RS
DB0
52
1
Armature Winding BSM 275
DB011
1
Ball Bearing 608
-
2Z
DB0
53
2
Raised Head Screw
M4x100 DIN84
DB0
54
1
A
ir Ring
DB014
2
Insulating Plate
DB017
4
Spring Washer M5 DIN 7980
DB0
56
1
heese Heat Screw M5 x 8
5 DIN 912
DB019
2
heese Heat Screw 2,9 x 9,5 DIN 7971
DB022
1
Raised Head Screw 3,9 x 19 DIN 7981 G
DB023
1
Handle BSM 270 green
DB025
1
Stopper
DB027
1
Raised Head Screw 3,9 x 25 DIN 7981 G
DB028
1
Raised Head Screw 3,9 x 13 DIN 7981 G
DB029
1
Handgrip Black
DB030
1
Switch ON
-
OFF
DB0
48
1
Ball Bearing 626
-
2Z
DB034
1
Shaft BSM 270
–
280
DB036
1
Drive Unit BSM 270, 230 V, 800 W, green
DB03
7
1
apacitor 2007 BSM 270
DB0
55
1
Field 230 V
DB039
1
Motor ase Green
DB040
2
arbon Holder BSM 270
DB041
2
arbon Brush BSM 270

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 27

Operating Instructions
DOHLE Hand Welding Extruder ExOn3A
DOHLE Extrusionstechnik GmbH 28
Welding Shoes
a
s
s
s
s
X - weld
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 weld corner weld
V-seam
overlap weld
thickness of material order - no.
welding shoe, round
width of weld B
welding 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