Munsch MM-Xtruder User manual

MUNSCH Kunststoff-Schweißtechnik GmbH Ausgabe 11.2006/Rev.00 Seite 1 von 28
Operating Instructions
Type: MM-Xtruder Serial No.:
230 Volt / 115V P.O. No.:
P.O. date:
for Hand Extruder Ident No.
230V K03969
115V K04180
These operating instructions contain important information to
be observed for hand extruder operation and maintenance.
It is therefore imperative that the operating instructions be read and
their contents fully understood by the operators before the hand
extruder is being placed in service.
MUNSCH Kunststoff-Schweißtechnik GmbH
Im Staudchen •D-56235 Ransbach-Baumbach
P.O. Box 142 •D-56221 Ransbach-Baumbach
Germany
Phone: [phone]
Fax : [phone]
Internet: http://www.munsch.de
E-mail: [email protected]

Hand Extruder MM-Xtruder
Munsch Kunststoff-Schweißtechnik GmbH Edition 11/2006/Rev00 Page 2 of 28
Scope of delivery:
Please check if the delivery is complete.
The delivery comprises:
1 hand extruder 1 hot air hood
1 extruder stand 1 set of mounting tools
1 welding shoe, machined 1 transport case
3 air nozzles

MM-Xtruder Edition 11.2006/Rev. 00 Page 3/28
Contents
1GENERAL......................................................................................................................................................................5
2SAFETY..........................................................................................................................................................................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
2.4 SAFE WORKING PRACTICES ........................................................................................................................................6
2.5 SAFETY INSTRUCTIONS FOR OPERATOR /OPERATING PERSONNEL..............................................................................6
2.6 SAFETY INSTRUCTIONS FOR MAINTENANCE,INSPECTION AND MOUNTING .................................................................8
2.7 UNAUTHORIZED MODIFICATIONS AND SPARE PARTS..................................................................................................8
3TRANSPORT AND STORAGE ...................................................................................................................................9
3.1 TRANSPORT ...............................................................................................................................................................9
3.2 STORAGE ...................................................................................................................................................................9
3.3 RETURN TO MUNSCH ..............................................................................................................................................9
4PRODUCT DESCRIPTION .......................................................................................................................................10
4.1 ALLOWABLE SERVICE RANGE ..................................................................................................................................10
4.2 GENERAL DESCRIPTION ...........................................................................................................................................10
5STARTUP AND SHUTOFF........................................................................................................................................11
5.1 GENERAL.................................................................................................................................................................11
5.2 PREPARATION..........................................................................................................................................................11
5.3 STARTING THE HAND EXTRUDER .............................................................................................................................12
5.4 WELDING WITH THE HAND EXTRUDER .....................................................................................................................13
5.4.1 Introducing the welding rod............................................................................................................................13
5.4.2 Replacement and aging of welding rod...........................................................................................................13
5.4.3 Welding direction / rate ..................................................................................................................................14
5.4.4 Work interruptions..........................................................................................................................................14
5.4.5 Shutoff.............................................................................................................................................................14
5.4.6 Transport/Storage...........................................................................................................................................15
5.5 SET TEMPERATURE ON TEMPERATURE CONTROLLER ...............................................................................................15
5.5 Set temperature on temperature controller.............................................................................................................15
6MAINTENANCE / REPAIR.......................................................................................................................................19
6.1 MAINTENANCE /INSPECTION OF HAND EXTRUDER TYPE MM-XTRUDER .................................................................19
6.2 DISMANTLING..........................................................................................................................................................19
6.2.1 Hand extruder type MM-Xtruder ....................................................................................................................19
7MALFUNCTIONS, CAUSES AND REMEDIES......................................................................................................22
7.1 TROUBLE-SHOOTING ...............................................................................................................................................22
7.2 FAULT DIAGNOSIS....................................................................................................................................................22
8TECHNICAL DATA ...................................................................................................................................................24

Hand Extruder MM-Xtruder
Munsch Kunststoff-Schweißtechnik GmbH Edition 11/2006/Rev00 Page 4 of 28
Konformitätserklärung 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-Schweißtechnik GmbH
Im Staudchen
D-56235 Ransbach-Baumbach
declare on their own behalf and responsibility that the hand extruder
Machine type: Hand Extruder
Type designation: MM-Xtruder
to which this declaration refers conforms to the following standards, codes and regulations:
EU Machinery Directive 98/37/EC EU EMC Directive 89/336/EEC
EN 61029-1 (VDE 0740 Part 500) DIN EN 61000-6-2
VDE 0701 Part 1 DIN EN 61000-6-4
VDE 0702 Part 1
EU Low-Voltage Directive 73/23/EEC
EN 60204-1 (VDE 0113 Part 1)
Conformance of this industrial tool with the above codes and 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 void this declaration, unless expressly approved in writing by the manufacturer.
Ransbach-Baumbach, November 2006 Dipl.-Ing. Stefan Munsch
Managing Director

MM-Xtruder Edition 11.2006/Rev. 00 Page 5/28
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.
Any person performing work with/on the hand
extruder is required to read the operating
instructions. Such work includes, for instance:
•operation,
•maintenance (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 be always 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 responsible specialist
personnel/Operator before mounting and starting-up
the hand extruder and that they be always available
at the place of use.
Operating reliability of the hand extruder
presupposes that the instructions under section
“General” of these operating instructions are
complied with. In no case must the limit values
indicated be violated.
Intact and unaltered hand extruders are in
conformance with the applicable codes and
standards and meet all regulatory limit values
regarding EMC (electromagnetic discharges and
interference immunity). Nevertheless, they 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 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.

Hand Extruder MM-Xtruder
Munsch Kunststoff-Schweißtechnik GmbH Edition 11/2006/Rev00 Page 6 of 28
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, operating and safety procedures issued by the
Operator are to be followed.
2.5 Safety instructions for Operator /operating
personnel
•Before placing the hand extruder in service,
check that 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 §55, the hand extruder is
to 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) (115V)²
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 the required 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. 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
2) for 115 V AC

MM-Xtruder Edition 11.2006/Rev. 00 Page 7/28
•Extension cables must be certified for the
respective 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 mains connector or
connecting cable with wet hands. Hold the cable
always at the connector when plugging or
unplugging it.
•CAUTION When using a power set for power
supply, the set must have the following rated
output:
≥4 x rated output of hand extruder
•Never allow the hand extruder to come into
contact with water as this may cause a hazard to
persons, damage to equipment and short-
circuiting.
•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
environments.
Make sure to stand on a firm base when
operating the hand extruder.
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 450 °C.
- Attachments may be damaged by the weight of
the hand extruder or may be impaired in their
function.
- Bare metal parts must not come into contact
with other items during the work or breaks (e.g.
cooling).
B
ILD D02-0001
•Contact of combustible components
with hot bare metal parts poses a fire risk!
Do not use synthetic gloves!
D02-0001

Hand Extruder MM-Xtruder
Munsch Kunststoff-Schweißtechnik GmbH Edition 11/2006/Rev00 Page 8 of 28
•Do not direct the hot air jet of the hand extruder
toward living beings or temperature-sensitive
items.
Safety distance : 2 m radius
B
ILD D02-0002
•Use suitable personal protection equipment for
overhead work (e.g. hard hat, goggles, gloves,
protective clothes) to guard against falling items.
•During work breaks and after completion of the
welding job, place the hand extruder on the rests
supplied for this purpose.
CAUTION The hot air hood must be remounted.
Make sure that the hand extruder is firmly
positioned!
Deposit hand extruder in a dry location.
After finishing work, cool the hand extruder to
safe-to-touch temperature, using the air supply
system.
•Do not operate, dismantle or carry out
modifications on the hand extruder, if
- the connecting cable or the mains connector is
defective,
- safety devices are damaged,
- foreign matter or liquid has penetrated the
hand extruder,
- the unit does not work properly or there are
unusual changes in the operating behaviour.
•Never allow the hand extruder to come into
contact with water as this may cause a hazard to
persons, damage to equipment as well as short-
circuiting.
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 operation
instructions.
•As a rule, the hand extruder must be shut off and
the connector unplugged before proceeding to
any work on the unit. The shutoff procedure for
the hand extruder described in the operating
instructions must be strictly followed.
•Electrical hazards are to 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 are required.
•Ensure the safe and environment-friendly
disposal of utilities, auxiliaries and replaced parts!
•Remount and reactivate all safety and protective
devices immediately on completion of the welding
job.
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 Manufacturer’s
liability for any resulting damage.
D02-0002
360°
2m(6ft)

MM-Xtruder Edition 11.2006/Rev. 00 Page 9/28
3 Transport and Storage
3.1 Transport
•Before transport or storage, make sure
that the hand extruder has cooled down to
safe-to-touch temperature.
•The hand extruder may only be held and
touched on the handles provided for this purpose.
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
450 °C during operation.
FIG. D02-0001
•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 hand extruder!
MUNSCH’s original shipping case or the transport
cases offered by MUNSCH are recommended for
transport.
3.2 Storage
•Store the hand extruder in a dry and frost-free
place.
•Protect the hand extruder from unauthorized
access.
•Special preservation is not required.
3.3 Return to MUNSCH
Should it become necessary to return the hand
extruder to MUNSCH Kunststoff-
Schweißtechnik GmbH, always use the original
shipping case.
D02-0001

Hand Extruder MM-Xtruder
Munsch Kunststoff-Schweißtechnik GmbH Edition 11/2006/Rev00 Page 10 of 28
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 limit
values indicated in these operating instructions.
CAUTION Operation of the hand extruder outside
the allowable service range stated in these operating
instructions is subject to the Manufacturer’s prior
approval.
4.2 General description
The type MM-Xtruder is a hand extruder with
integrated air supply (Autoair).
CAUTION!
Use 3mm welding rod exclusively.
CAUTION Too low a speed will pose 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 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 parts to be jointed is achieved by a
preheat nozzle (5) which is supplied from an
integrated hot air unit (6). Air supply is via an on-
board blower.
Melt and preheat air temperatures are controlled
separately. The setpoint and actual values are
displayed concurrently.
For the drive interlock to be released for starting, the
melt and preheat air temperatures must be above
the respective start release temperatures, which
can be separately set.
The temperature-controlled start interlock prevents
the drive from starting if there is still unmolten
material in the extruder, thus forestalling damage to
the machine.
The output rate is variable so that the weld thickness
and preheat time can be matched with each other.