WELDY booster EX2 User manual

booster
EX2
booster
EX3
Weldy AG
Galileo-Strasse 10
CH-6056 Kaegiswil / Switzerland
Tel. [phone]
Fax [phone]
www.weldy.com
GB

2
Please read operating instructions carefully before use
and keep for further reference.
Operating Instructions (Original operating instructions)
WELDY booster EX2 / EX3
Extrusion Welder
GB
DANGER!
Danger when opening up the tool, as live components and connections are
exposed. Therefore, before opening, unplug the tool to ensure disconnection
from the mains. Electronically conductive material (e.g. PE-EL) must not be welded.
Danger of fire and explosion! Incorrect use of the hand extruder (e.g. over-
heating of the
material) can present a fire and explosion hazard, especially near
combustible materials and explosive gases.
Danger – can cause burns! Do not touch bare metal parts and emerging
material while hot. Allow the device to cool. Do not direct stream of hot air or
emerging material towards people or animals.
Warning
The tool must be operated under supervision. Heat can ignite flammable
materials which are not in view. The machine may only be used by qualified
specialists or under their supervision. Children are not authorized to use
this machine.
For personal protection on building sites we strongly recommend the tool be
connected to a RCCB (Residual Current Circuit Breaker).
Protect tool from damp and wet.
FI
Caution
Application
Welding PE and PP thermoplastics for applications in:
• containerengineering • pipelineconstruction
• plasticfabrication • landllsitesandabandonedpollutedareas
The voltage rating stated on the tool must correspond to the mains voltage.
If power failure occurs, the hot air blower switch and drive must be switched o
(release locking device).
120
230
Repairs should only be carried out by Weldy partners. Restricted to use with origi-
nal Weldy accessories and spare parts.

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Technical Data
Technical data and specifications are subjected to change without prior notice.
Welding output booster EX2 booster EX3
Welding rod mm
(in accordance with DVS 2211) Ø 3 / Ø 4 Ø 3 / Ø 4
Ø3; Welding output [ kg/h ]
(Average values at 50 Hz)
PE 1.5 PP 1.5 PE 2.4 PP 2.4
Ø 4; Welding output [ kg/h ]
(Average values at 50 Hz)
PE 2.2 PP 2.2 PE 3.4 PP 3.4
booster EX2 booster EX3
Voltage V~
Mains voltage is not reversible 230 230
Power consumption W 3000 3000
Frequency Hz 50 / 60 50 / 60
Air temperature °C max. 360 max. 360
Plasticizer temperature °C max. 310 max. 310
Size L ×W ×H mm
without welding shoe 500 ×250 ×410 630 ×250 ×410
Weight kg
incl. 3 m cable 6.4 6.9
Certification scheme
cable & plug
Protection class II
4 4
Power tools, accessories and packaging should be recycled. For EU countries only: do not di-
spose of power tools in your household rubbish! According to the European Directive 2002/96
on waste electrical and electric equipment and its implementation in national law, power tools
which can no longer be used must be collected separately and recycled.
Disposal

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Description of tool
1. Welding shoe
2. Hot air tube group
3. Tool rest
4. Welding rod opening
5. Hot air blower
13
34
12
1
2
3
4
5
10
11
6
7
8
9
6. Tail handle
7. Drive unit
8. Overload protection fuse
9. Locking device drive on/o switch
10. Tool drive on/o switch
11. Handle
12. Air temperature potentiometer
13. Hot air blower switch
Instruction for tool switch:
• For starting the tool press and hold tool drive on/o switch (10)
• For stopping the tool release tool drive on/o switch (10)
• While holding tool drive on/o switch (10) press locking device drive on/o switch (9) for automatic
mode.
Before turn on power supply, all switches have to be turned o and make sure potentiometer is at «0».
Preparation for welding
The hand extruder must not be operated in inflammable environments or where explosion hazards
exist. Ensure stable position during operation. The connection cable and the welding rod must remain
unimpeded and must not hinder the user or others during operation.
Ensure power supply voltage is single phase 220V~230V,
with minimum power load capacity of 3000 W.
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5
Preparation for welding
Length
[m]
Minimum cross-section (at ~230V)
[mm2]
up to 19 2.5
20 – 50 4.0
• The handle (11) can alternatively be mounted left, right or bottom of the tool.
• Ensure the minimum cross-section when using extension cables. The extension cable must be approved for the
site of use (e.g. in the open air) and marked correspondingly. When using a power unit for power supply, it’s
nominal power rating is: 2 x nominal power rating of the hand extruder.
Starting the welding process
• Fit the required WELDY welding shoe (1) according to the paragraph “change of the welding shoe”.
• Welding can begin once the operating temperature has been attained.
Operate the tool drive on/o switch (10) for this purpose, operate the tool only when feed welding rod of 3 or
4 mm diameter into the welding rod opening (4) and allow a small amount plasticized material to escape.
• Adjust the heat of the tool until it reaches the ideal temperature to start the work.
Starting protection
The tool is equipped with current overload protection fuse (8). In case of too high current consumption,
the drive will switches o automaticaly, in result of hold starts or if the material in the screw is insu-
ciently plasticized. Wait for 1 minute; press the overload protection fuse (8), the tool will re-start again.
• Connect the WELDY hand extruder to the mains supply.
• Switch on the tool at the hot air blower switch (13).
• Adjust the hot air temperature by the air temperature potentiometer (12) to position 7.
Switching on
In order to reach the operating temperature the tool needs to heat up
for at least 10 minutes.
DANGER!
Never feed welding rod into both welding rod openings at the same time.
Keep the welding rod feed clean and dry.
Heating
(position 7)
Start-up waiting period:
10 minutes Ready

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Starting the welding process
• Carry out test welding and analyse.
• For interrupting material extrusion use the tool drive on/o switch (10).
• Direct the welding shoe (1) to the welding zone.
• Pre-warm the welding zone with back and forth movements.
• Position the tool on the prepared welding zone and operate the tool drive on/o switch (10).
• Carry out test welding and analysis.
• Adjust the hot air temperature using the air temperature potentiometer (12).
• In case of a prolonged welding process, locking device drive on/o switch (9) can be held in the active state
with the locking tool.
• Make sure there is enough clean welding rod on your unwinding unit.
• The welding rod is pulled in through the welding rod opening (4) automatically after starting. The welding rod
pull-in must not be impeded.
• Release the locking device drive on/o switch (9) by briefly pressing the tool drive on/o switch (10)
and then letting go. Remove welding material from the welding shoe in order to avoid damage on the
welding shoe when starting the next time.
• The tool must only be laid down on the tool rest (3).
• Adjust the air temperature potentiometer (12) to «0», let the tool to be cool down.
• Switch off the hot air blower switch (13).
Switching o
Checking the temperature of the extruded material and the pre-heating temperature
The temperatures of the extruded material and the hot air jet are to be checked at regular intervals when carrying
out welding work over an extended period: Fast display electronic temperature measuring tools with the appro-
priate temperature probes have to be used. The highest temperature in the hot air jet between the nozzle outlet
plane and a depth of 5 mm is to be determined. The measurement probe must be inserted in the welding shoe in
the middle of the extruded material to measure its temperature.
Use a fireproof base.
Front metal of tool and welding material is of high temperature
while tool is working, do not touch them to avoid burning.
The hot air jet must not be directed towards persons and objects.
• The welding shoe (5) can be turned infinitely
to the desired welding direction by loosening the
clamp screws (18).
• The clamp screws (18) must be well tightened
again.
Welding direction
The welding shoe must only be changed when the tool has attained its operating
temperature. Work with temperature resistant gloves only.
5 18

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Danger of getting burned!
Work with temperature
resistant gloves only.
• The welding shoe must only be changed when the tool has attained its operating temperature.
Changing the welding shoe
Switch o the hot tool and disconnect it
from the mains supply.
5 Welding shoe
17 Welding shoe holder
18 Clamp screws
19 Extruder nozzle
20 Screws for welding shoe
21 Pre-heating nozzle
Welding direction
Replacement of carbon brushes (drill machine)
Disassembly:
• Turn o the tool while warm and disconnect from the power supply.
• Remove the welding shoe holder (17) by unfastening the clamp screws (18) from the extruder nozzle (19).
• Every time the welding shoe is changed, clean the extruder nozzle (19) of welding residue and make sure that
it is screwed in tightly.
• Remove welding shoe (5) from the welding shoe holder (17) by unfastening the fastening screws for
welding shoe (20).
Assembly:
• Clean the extruder nozzle (19) with the brush.
• Fasten a welding shoe (5) appropriate to the welding seam onto the welding shoe holder (17) with
fastening screws for welding shoe (20). The welding shoe (5) and welding shoe holder (17) must be
tightened properly with the screws for welding shoe (20).
• Attach welding shoe unit (17) + (5) to the extruder nozzle (19) tightly by clamp screws (18).
1. Unscrew the carbon brush cap.
2. Take out the carbon brush.
3. Put on the new carbon brush and screw cap on.
5
5 18
21 18
20
19
18
17
5
18
1.1 1.2 23.1 3.2
max. 2 mm
Type Material/Diameter Recommended step blower
booster EX2 PE ( Ø 3 / Ø 4) PP ( Ø 3 / Ø 4) 7
booster EX3
PE ( Ø 3 / Ø 4) PP ( Ø 3 / Ø 4) 7
Noted: the potentiometer steps depend on the environment temperature and material used.
Recommended potentiometer steps on hot air blower:
Switch o the hot tool and disconnect it
from the mains supply.

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Maintenance
• In case of soiling clean the air inlet on the hot air blower with a brush.
• Clean the extruder nozzle (19) each time the welding shoe is replaced and remove any welding deposits.
• Check power supply cord and plug for electrical and mechanical damage.
• Regularly clean the air hose.
Service and Repairs
• Ensure the carbon brushes of the drive and hot air blower checked by your service center after 100 hours
of operation. The drive and the hot air blower switch off automatically once the minimum carbon length
has been reached.
• Repairs should only be carried out by authorized Service Centers. ONLY original spare parts in accordance
with the circuit diagram and spare parts list must be used.
Warranty
• For this tool, the guarantee or warranty rights granted by the Weldy-partners shall apply. In case of guaran-
tee or warranty claims any manufacturing or workmanship defects will either be repaired or replaced by the
Weldy-partners at its discretion. Warranty or guarantee rights have to be verified by an invoice or a delivery
document. Heating elements shall be excluded from warranty or guarantee.
• Additional guarantee or warranty claims shall be excluded, subject to mandatory provisions of law.
• Warranty or guarantee shall not apply to defects caused by normal wear and tear, overload or improper hand-
ling.
• Warranty or guarantee claims will be rejected for tools that have been altered or changed by the purchaser.
Blank V Seam Fillet
weld
Overlap
seam
Corner
seam
outside
Corner
seam
short
Corner
seam
long
Accessories
• Only WELDY accessories must be used.
• WELDY oers the right welding shoes for dierent common types of seam:

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10

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Your partner:
BA booster EX2/EX3/11.2014 Art. 141.168
Weldy AG
Galileo-Strasse 10
CH-6056 Kaegiswil /Switzerland
Tel. [phone]
Fax [phone]
www.weldy.com
© Copyright by Weldy