Munsch GM-50-FU User manual

MUNSCH Kunststoff-Schweißtechnik GmbH Issue 12.2009/Rev. 01 Page 1/15
Operating Instructions
Type:
GM-50-FU
Serial No.:
Article No.: K02912
These operating instructions contain important
information to be observed for extruder operation
and maintenance.
It is therefore imperative that they be read and their
contents fully understood by the operators before the
extruder is placed in service.

Extruder GM-50-FU
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Scope of delivery:
Please check that the delivery is complete.
The delivery comprises:
1 extruder 2 compression nozzles
1 control cabinet 1 hot air hood
1 welding shoe, machined
3 preheat nozzles
2 nozzles
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 O PERATOR / 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 M UNSCH .................................................................................................................................................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 EXTRUDER .......................................................................................................................................10
5.4 W ELDING WITH THE EXTRUDER ...............................................................................................................................11
5.4.1 Introducing the welding material....................................................................................................................11
5.4.2 Replacement and aging of granulate...............................................................................................................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 ...............................................................................................................................13
6.1 M AINTENANCE / INSPECTION OF EXTRUDER ..............................................................................................................13
6.2 D ISMANTLING ..........................................................................................................................................................13
6.2.1 Overview of spare parts/attachments..............................................................................................................13

GM-50-FU Issue 12.2009/Rev. 01 Page 3/15
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
Type designation: GM-50-FU
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

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1 General
These operating instructions must always
be available at the place of use of the extruder.
The objective of these operating instructions is to
support operators in familiarizing themselves with
the 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 extruder. Their
observance helps avoid danger, minimize repair
costs and downtimes, enhance reliability, and extend
the service life of the extruder.
These operating instructions must be observed by all
persons working with/on the extruder. Such work
includes, for instance:
•operation,
•maintenance, inspection and repair
•transport.
The 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 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 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 extruder in service and that they
always be available at the place of use.
Safe operation of the 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 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 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.

GM-50-FU Issue 12.2009/Rev. 01 Page 5/15
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 extruder and its functions are marked
with
CAUTION
Instructions directly indicated on the 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 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.
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 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 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 extruder must be
operated via a residual current-operated circuit
breaker or an isolating transformer.
•CAUTION During extruder operation (under load),
a voltage of 400 V 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.

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•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 extruder to come into
contact with water: Hazard to persons and
equipment, short-circuit risk.
•CAUTION Never operate the extruder without
air supply; risk of extruder damage.
•The extruder must not be used in
explosion hazard areas or flammable
atmospheres.
Make sure that the extruder is firmly positioned
during the extrusion welding job.
The connecting cable must be freely movable and
must not obstruct the operator or third parties in
their work.
•
- 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 extruder.
- Bare metal parts must not come into contact
with other items during the work or work
breaks (e.g. cooling).
•Contact of combustible components
with hot bare metal parts poses a risk of fire!
Do not use synthetic gloves!

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•Do not direct the hot air jet of the extruder
towards living beings or heat-sensitive items.
Safety distance: 2 m radius
•Use suitable personal protection equipment for
overhead work (e.g. hard hat, safety goggles,
gloves, protective clothes …) to guard against
falling items.
CAUTION The hot air hood must be remounted.
Make sure that the extruder is firmly
positioned!
Deposit the extruder in a dry location.
After completion of the welding job, cool the extruder
to safe-to-touch temperature, using the air supply
system.
•Do not operate, dismantle or carry out any
modifications on the extruder, if
- the connecting cable or the mains connector
is defective,
- safety devices are damaged,
- foreign matter or liquid has penetrated into the
extruder,
- the unit does not work properly or there are
unusual changes in its operating behaviour.
•Never allow the extruder to come into
contact with water: Hazard to persons and
equipment, short-circuit risk.
2.6 Safety instructions for maintenance,
inspection and mounting
The Operator is responsible for ensuring that
maintenance, inspection and mounting activities are
performed by authorized and qualified personnel
who are thoroughly familiar with the operating
instructions.
•As a rule, the extruder must be shut off and the
connector unplugged before proceeding to any
work on the unit. The shutoff procedure for the
extruder described in the operating instructions
must be strictly observed.
•Electrical hazards must be ruled out (for details,
see VDE guidelines and the standards of your
local electric utility, for instance).
•VDE 0701 (IEC 335) prescribes the
measurement of the protective conductor
resistance, insulation resistance and leakage
current after each repair or modification to
electrical equipment. Furthermore, a visual
inspection of the unit and its connecting cable as
well as voltage and current measurements and a
function test must be carried out.
•Ensure the safe and environmentally compatible
disposal of media, auxiliary materials and
replaced parts!
•Remount and reactivate all safety and protective
devices immediately on completion of the
maintenance, inspection or repair work.
2.7 Unauthorized modifications and spare parts
Modifications or changes to the unit are only allowed
after consultation with the Manufacturer. In the
interest of safety, only original spare parts and
accessories authorized by the Manufacturer should
be used. The use of components other than the
original spare parts may invalidate the
Manufacturer’s liability for any resulting damage.
D02-0002
360°
2m(6ft)
D02-0002
360°
2m(6ft)

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3 Transport and Storage
3.1 Transport
•Before transport and storage, make
sure that the extruder has cooled down to
safe-to-touch temperature.
•
Do not touch bare metal parts (including the hot
air hood) – whether with or without gloves -
before having made sure that they are safe to
touch. These parts reach temperatures of up to
350 °C during operation.
•
•Always transport or store the extruder in such a
way as to preclude any mechanical loads on the
attachments.
If parts have been removed for transport
purposes, mount and fasten them carefully before
restarting the extruder!
Transport of the extruder in MUNSCH’s original
shipping case is recommended.
3.2 Storage
•Store the extruder in a dry and frost-free place.
•Protect the extruder from unauthorized access.
•Special preservation is not required
3.3 Return to Munsch
Should it become necessary to return the
extruder to MUNSCH Kunststoff-Schweißtechnik
GmbH, always use the original shipping case.
4 Product Description
4.1 Application range
The application range of the extruder is defined by
the data on the type tag and the service limits
indicated in these operating instructions.
CAUTION Operation of the extruder outside the
service limits stated in these operating instructions is
subject to the manufacturer’s prior approval.
4.2 General
Type GM-50-FU is a extruder with integrated air
supply (Autoair).
The following operating parameters can be freely
selected:
- welding rate,
- hot air temperature,
- melt temperature and throughput; the melt
throughput can be varied within a range of 20 Hz
to 70 Hz by decreasing or increasing the
frequency set on the POTI on the control cabinet.
- Moreover, the composition and shape of the
granulate have an influence on the melt
throughput.
Driven by a powerful electric motor (1), the granulate
is fed from hopper (2) into the extruder (3). The
extruder screw forces the granulate into the extruder
nozzle, melting it into a homogeneous, completely
plastified mass. As the molten material exits the
extruder nozzle, it is moulded by a welding shoe (4)
to the geometry of the weld seam to be deposited.
Preheating of the base material to be joined is
accomplished by a preheating nozzle (5) which is
supplied with hot air from an integrated hot air unit
(6).

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Melt and preheat temperatures are controlled
separately. The setpoint and momentary values are
displayed concurrently.
The melt and hot air must have reached the preset
start interlock temperatures for the drive to be
released by the start interlock. The start interlock
temperatures for the melt and hot air temperatures
are separately preset.
The temperature-controlled start interlock prevents
the drive from starting if there is still unmolten
material in the extruder, thus precluding damage to
the unit.
The output rate is variable so that the preheat time
can be matched to the weld thickness.
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 starting / shutting off the extruder, make sure
to carefully read the instructions under section
“Safety”.
Only trained and qualified personnel may be
assigned to the operation of the extruder.
5.2 Preparation
•Place the extruder on a firm support (minimum
load bearing capacity: 100 kg) and secure it
against toppling over. Next, secure the extruder
to the support using the 4 screw holes provided
on the gearbox.
•Mount hot air hood

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•Mount welding shoe
- Select the welding shoe required for the
specific weld geometry or machine a welding
shoe blank to the required geometry.
- Observe DVS 2207 Guideline, Part 4 for
machining welding shoe blanks.
- Mount welding shoe to the hand extruder in
the position required for welding.
Observe welding direction!
Tighten set screw (25).
•Mount preheat nozzle
- Select and mount the preheat nozzle (4)
required for the specific weld geometry.
- Observe spacing A = 5 mm.
- Tighten the preheat nozzle using mushroom
head screw (125.22).
Table: Preheat nozzle
Care must be taken to ensure that the preheat
nozzle provides intensive and uniform preheating
(melting) of the base material over the entire joint
width at as low a hot air temperature as possible.
5.3 Starting the extruder
Observe section “Safety“.
•CAUTION Never operate the extruder without air
supply. Otherwise the unit may suffer severe
damage.
•CAUTION Before plugging in the mains
connector, check that the drive unit is switched
off.
•CAUTION The hot air hood must be in place.
•CAUTION Plug in mains connector.
•CAUTION The on-board blower must start
automatically.
•CAUTION Once air exits the preheat nozzle (4),
the heating systems for the air/melt temperatures
may be activated.
•For the operation of the temperature controller,
see section 5.5 “Set temperatures“. For
temperature settings, see page 12.
•The hand extruder will reach its operating
temperature after about 10 to 15 minutes.