MANDREL welder RSX01 Manuale utente

Instruction Manual

Bedienungsanleitung

Suitable for: Nylon (PA) / PP / TPEE

RSX01

Friction welder for mandrels

Version 115V

Version 230V

ENGLISH

CONTENT

1 Safety notes

1.1 General notes on safety...................................................................................... 3

1.2 Intended use ...................................................................................................... 3

1.3 Incorrect use...................................................................................................... 3

1.4 EC declaration of conformity ............................................................................. 3

1.5 Scope of supply ................................................................................................. 4

1.6 Optional accessories.......................................................................................... 4

2 Commissioning

2.1 Prior to taking the machine into service ............................................................ 5

2.2Operating elements ............................................................................................ 5

2.3 Safety instructions............................................................................................. 6

2.4 Work sequence / welding parameters................................................................ 7

3 Service / Maintenance

3.1 Shipping information.......................................................................................... 8

3.2Preventive maintenance ..................................................................................... 8

3.3 Repair ................................................................................................................. 9

3.4 Warranty ............................................................................................................ 9

3.5 Storage............................................................................................................... 9

3.6 Disposal / Environmental compatibility.............................................................. 9

4 Technical data

4.1 Rating data....................................................................................................... 10

4.2 Conditions for use............................................................................................ 10

NOTES MARKED ON THE MACHINE AND

IN THE OPERATING INSTRUCTIONS:

Warning of a potential danger, follow with instruction manual

Reference! Please use utmost attention.

Disposal. Friendly-to-the-environment disposal.

Read all safety warnings and all instructions.

Wear safety glasses and ear protection.

1.1 GENERAL NOTES ON SAFETY

This operation manual is applicable for the machine RSX01 230V / 115V.

The machine may only be handled by personnel who are qualiﬁed.

Hold power tools by insulated gripping surfaces when performing an operation where

the cutting tool may contact hidden wiring or its own cord. Contact with a «live» wire will

make exposed metal parts of the tool «live» and shock the operator.

WARNING! Read all safety warnings and all instructions. Failure to follow the

warnings and instructions may result in electric shock, ﬁre and/or serious injury.

Save all warnings and instructions for future reference.

1.2 INTENDED USE

The machine is designed as a hand-guided machine or stationary with use of the provided

mounting adapter for welding mandrels made of nylon (PA) / PP / TPEE.

1.3 INCORRECT USE

All uses other than those described under section 1.2 are regarded as incorrect use and

are therefore not admissible.

The motor is supplied without current limitation, therefore the unit must not be

used in continuous operation. The unit may therefore operate permanently in the

overload range and damage due to overheating cannot be excluded!

1.4 EC DECLARATION OF CONFORMITY

Continuous double or reinforced insulation according to class II IEC 536.

The conformity mark conﬁrms that the applicable directives have been complied

with. The EMC directive (2014/30/EU) with standard EN55014 is fulﬁlled.

The Low Voltage Directive (2014/35/EU) with standard EN 61010-1 is fulﬁlled. The

Machinery Directive (2006/42/EC) with standard EN60745 has been met.

Glottertal, 3/2019 · Markus Beha, Managing Director, BEHA Innovation GmbH

1.5 SCOPE OF SUPPLY

1 pc. Friction welding

machine RSX01

1 pc. Mounting adapter 1 pc. Tool for

release clamping jaws

1 pc. Allen socket wrench

1 pc. Assortment box

for clamping jaws

1 Set Clamping jaw

adapter

1 pc. Instruction

manual

NOT INCLUDED IN SCOPE OF SUPPLY

Please note that it is mandatory to use clamping jaws for the operation of

the RSX01. Please ask for the required clamping jaw geometry for your

application.

1 Set of clamping jaws narrow up to Ø16mm

(Use with clamping jaw adapter)

1 Set of clamping jaws wide from > Ø16mm

(Use without clamping jaw adapter)

1.5.1 OPTIONAL ACCESSORIES

Edge cutter SE02

for welding bead cleaning

Ratchet Cutters and/or spare blades

for straight mandrel cut

2 COMMISSIONING

2.1 PRIOR TO TAKING THE MACHINE INTO SERVICE

Check the condition of the machine for damage before use.

Observe national regulations.

Take protective measures.

2.2 OPERATING ELEMENTS

1) Drive motor 2) Speed controller

3) ON/OFF switch 4) Excentric drive

5) Clamping device 6) Clamping lever

7) Release button 8) Adjusting knob for welding pressure

9) Clamping jaws adapter 10) Hexagonal head bolt to clamp the proﬁle

11) Mounting adapter for stationary use

On Off

Off

3 3

2.3 SAFETY INSTRUCTIONS

For all work, the applicable accident prevention regulations of the professional

association must be observed.

The appliance may only be connected to the input voltage speciﬁed on the name-

plate.

If the safety of the operator can no longer be guaranteed, the appliance must be

taken out of operation and secured against unintended use.

displays obvious damage

no longer performs the desired functions

was stored for too long under unfavourable conditions

was exposed to mechanical stresses during transport

During the welding process melted welding material can be thrown out of the

machine. While operating the machine it is essential to wear safety glasses and

protective long-sleeved clothes (danger of burns).

Use the machine only in large and / or ventilated areas.

Switch on the machine only when mandrel is clamped, otherwise the clamping jaws

can be thrown out of the holder.

Never use the product in an explosive area.

Never use the product in a wet area. Avoid the contact to the device directly with

water.

Repairs should only be performed by trained persons. Please send the product to

an authorized Mandrelwelder service partner or directly to BEHA Innovation GmbH.

This machine is not designed for continuous operation. Risk of motor over heating

and damaging of the machine.

2.4 WORK SEQUENZE

Please note the safety instructions and warnings in point 2.3!

Select suitable clamping jaws for the hose mandrel geometry and insert them (at

(9)). Depending on the clamping jaw design, it is necessary to insert or remove the

clamping jaw adapters (9).

Move the clamping jaws apart while turning the outer hexagon (5) to the left with

the key until the clamping device engages.

Cut both ends of the hose mandrel to be connected ﬂat.

Insert the hose mandrel in the middle of the clamping jaws and hold it with the

clamping lever (6). Tighten the head bolt (10) with the Allen key. Repeat the proce-

dure for the other side.

There should now be a minimal welding gap between the two ends of the hose

mandrel (light gap).

Warning: It is not necessary to tighten the pull studs all the way if the belts are

ﬁxed in the RSX01 welding unit. It is sufﬁcient to clamp them tightly to prevent

the tubular mandrel from slipping out of the jaws. Too much tension can cause

damage to the tension bolts.

STOP

Adjust the speed controller (2) (steps 1 - 6) depending on the proﬁle to be welded.

Adjust the welding pressure on the setting knob (8).

Strongly pressed in position full welding pressure

Slightly depressed position half welding pressure

Material Speed Welding pressure

Ø <10 mm Ø >10 mm

3 ±1 full

welding pressure

half

welding pressure

Nylon (PA)

TPEE

Switch on the machine (3) Important: only with clamped hose mandrel, risk of

voiding parts (proﬁle jaws)!

After reaching the max. speed of the motor, start the welding process by pressing

the release button (7) (clamping jaws move together).

If a continuous welding bead has formed around the hose mandrel, switch off the

machine (3).

Welding process is ﬁnished.

Leave hose mandrel clamped for 2-3 min. in the machine to cool off.

Even after removing the hose mandrel, let it cool down for another 5 minutes before

the welding point is loaded.

To remove the hose mandrel, ﬁrst open the head bolt (10), only then move the

welding jaws apart with the external hexagon (5) to simplify the removal of the hose

mandrel.

Now the next welding process can be performed.

3 SERVICE / MAINTENANCE

3.1 SHIPPING TO THE BEHA-CUSTOMER SERVICE

Please always register the RSX01 friction welding machine by phone or e-mail

before sending it to BEHA customer service. The goods must always be declared

with the IncoTerm "DDP" (delivered duty paid). In this way you avoid a possible

rejection at customs and additional extra costs. Please refer to the return note for

the declaration of the repair (see www.mandrel-welder.com).

3.2 PREVENTIVE MAINTENANCE

To work effectively and surely keep the machine and the ventilation slots clean at all

times.

After an operating time of approx. 150-200 hours we recommend a preventive

maintenance of the RSX01 friction welding machine at an authorised BEHA service

centre.

3.3 REPAIR

Should the machine fail despite careful manufacturing and testing procedures, the

repair must only be carried out by an authorised BEHA customer service centre.

If it is necessary to replace the connecting cable, this must be done by the

manufacturer or his representative in order to avoid safety hazards.

3.4 WARRANTY

In the event of the tool being improperly handled, used for purposes for which it is

not intended and/or of the service and maintenance instructions not being observed

by non-authorized persons, no warranty shall be in effect for damages/consequen-

tial damages.

Complaints can only be honored if the machine is returned in the undisassembled

condition. Customer-speciﬁc modiﬁcations result in loss of warranty.

3.5 STORAGE

The device must be stored in a dry and closed room. If the unit has been transported at

extremely high temperatures, it must be acclimatised before being switched on until it is

completely dry.

Temperature range -15°...+50°C

Max. relative air humidity 90 % at 30°C

65 % at 50°C

3.6 DISPOSAL / ENVIRONMENTAL COMPATIBILITY

This machine consists of materials which can be disposed of in a recycling process.

Before disposal, render the machine unusable.

Do not throw the machine into the garbage collection.

According to national regulations this machine must be disposed of in an environ-

mentally-compatible recycling process.

4 TECHNICAL DATA

4.1 RATING DATA

Voltage 230V / 115V AC ± 10%

Frequency 50...60 Hz

R/min 3.500 - 15.000 (step 1 - 6)

Power 500 W

Vibration EN 60745 0,5 m/s2, K = 1,5 m/s2

Dimension 295 x 111 x 100 mm

Weight approx. 2,5 kg

The motor is supplied without current limitation, therefore the unit must not be

used in continuous operation. The unit may therefore operate permanently in the

overload range and damage due to overheating cannot be excluded!

The speciﬁed vibration value was measured using a standardised test procedure. It

can be used to compare products or for an initial assessment of the exposure.

Vibration emissions may differ from the speciﬁed value depending on how the device is

used. Operators must be protected by deﬁned safety measures based on the estimated

exposure under actual operating conditions.

4.2 CONDITIONS FOR USE

Temperature range during

operation 0°...+50°C

Relative Humidity 95 % at 10°C

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