MANDREL welder RSX01 Bedienungsanleitung
Instruction Manual
Bedienungsanleitung
Suitable for: Nylon (PA) / PP / TPEE
RSX01
Friction welder for mandrels
Version 115V
Version 230V
2
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.
3
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
4
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
5
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
1
11
On Off
On
Off
8
3 3
2
4
9
1
7
5
8
6
10
2
6
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.
7
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
PP
3 ±1 full
welding pressure
half
welding pressure
Nylon (PA)
TPEE
8
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.
9
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.
10
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
Inhaltsverzeichnis
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