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i m o t-*
^^LASTICmim^ECI^^
STARGUN
Ritmo S.p.A. is free t o modify the features of the machine described in this handbook a n d the intormation
contoined in it without any notice.
GB All righfs reserved. It is stricfly prohibited to reproduce this document or part of it in any form whatsoever.
L'entreprise Ritmo S.p A. Se reserve le droit d'apporter, sans pravis, toutes les modifications qu'elle dsirera aux
caractristiques de la machine dcrite dans c e manuel ainsi qu'aux informations qu'il contienf.
La reproduction d e c e document, mme partielle, sous n'importe quelle forme, est strictement interdite.
Ritmo S.p.A. se reserva el derecho d e hacer modificaciones sin previo aviso a las caractersticas d e lo mquina
descrita en este manual y a las informaciones en l incluidas.
Est terminantemente prohibida toda reproduccin de este documento, incluso parcial o de cualquier otra
A Ritmo S.p.A. pode efectuar sem pr-aviso quaisquer modificagoes as caractersticas da mquina descrita no
presente manual, b e m c o m o as informagoes nele inseridas.
A copia total ou parcial deste documento severamente proibida, sob qualquer forma.
Die hier angegebenen Daten sind ohne Gewhr und Ritmo S.p.A. behait sich Anderungen ohne Vorankndigung
vor.
D Pie Ven/ielfertigung, a u c h auszugsweise, dieses Dokumentes ist verboten.
Atmm
PLASTIC Hmm nmom S.p.A.
1. INTRODUCTION 2
Extruder 3
Welding shoes 3
3. PARTS DESCRIPTION 4
Machiine assembly 4
Thermoregulotor 5
4. SAFETY CRITERIA 6
5. WORKING HYGENE 8
6.^ Extruder 10
6.2 Execution 10
7.4 Checks 15
7.5 Welding 16
8. MAINTENANCE 16
9. TROUBLESHOOTINGS 17
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1. INTRODUCTION
Dear Customer,
Thank you for choosing o machine from the ritmo ronge of products.
This manual is designed to iliustrate the features and operating methods of your new extruder welder
model STARGUN. It contains all the necessary intormation and prescriptions for correct a n d safe use of
the equipment by professional operators. Please read oil parts of the manual carefully a n d keep it in o
safe place for futuro consultation and/or to transfer to any futuro owners/users of the machine.
We are confident that you will enjoy getting to know your new equipment and will b e oble to use it
profitably for many yeors to c o m e .
i t m o
PLASTIC miDIHE TECHNOLOeY
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2 . FIELD O F A P P L I C A T I O N
T E C H N I C A L FEATURES
FIELD OF APPLICATION
The STARGUN is a mini portable extruder adapt to the welding by extrusin of plstic material such as Polyethyiene
(PE), Polypropyiene (PP).
mmm
"V" weld "X" weld 90 weld Fillet weld Film weld Crner weld
TECHNICAL FEATURES
EXTRUDERS
The ronge of extruders STARGUN is mode by two modeis M-...20 and M-...40 in two different versions SB a n d CB, to
satisfy the different useoge needs. The main difference between the two models M-...20 a n d AA-...40 is the output per
hour of the extruded material, while the SB versin provide a self contoined blower a n d the CB versin provide a
blower to b e used with an air-compressor, both for the pre-heating of the material that need to be welded.
M-...20 M-...40
0 3 mm - 2,9 kg/h
0 3 m m - l,4kg/h
Max welding rafe 0 4 mm - 3,2 kg/h
0 4 mm - 1,8 kg/h
0 5 mm - 4,0 kg/h
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3. PARTS DESCRIPTION
MACHINE ASSEMBLY
1. Locking button
2. Motor starting button
3. Drill
4. Thermoregulotor,
5. Hot air blower
6. Welding shoe
7. Melting chamber
8. Rod feeder
9. Support welding shoe
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THERMOREGULATOR
5
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4. SAFETY CRITERIA
GENERAL
The use of STARGUN is reserved exclusively for troined a n d suitably skilled personnel in accordance v^ith the
regulations in forc.
Use the machine exclusively for the purpose described in section B. "FieId of applicotion" and in accordance wit*-
the operating a n d maintenance instructions. Any other type of utilization is considered os improper use and therefore
prohibited because of the risk of serious injury of operators, other persons and/or d a m a g e to the machine and othe-
property.
Immediately replace all worn or d o m o g e d parts using exclusively ritmo original spare parts.
All repairs on the machine must be performed by skilled and qualified personnel.
ELECTRICAL HAZARDS
^ ^ ^ ^ ^ ^
SHOCKING HAZARD
Context: DRILL AND BLOWER
O
MACHINE EARTH CONNECTION
(Check efficiency of connection)
Check that the electrical characteristics of the machine correspond to the
specifications of the power supply iine.
During connection phase between electrical boord and electrical line, verify the
presence of safety differential and magneto-thermol devices on electrical supply line
If necessary proceed with colibrafion.
Inlets on electrical board must be of type lEC 309 with mnimum protection grade IP4
Do not expose the machine to rain or other liquids.
Make sure that isoloting protections (for example gloves) are alwoys perfectly dry.
Do not expose electrical wiring or hydraulic hoses to chemical substances c
mechanical stress (e.g. pedestrian or vehicular traffic, contact with shorp objects
pulling, etc.).
Disconnect the power socket outlet from the electrical power supply when wori<
the machine has been concluded or temporarily suspended.
Before using the machine check the condition of individual electrical syste
components, particularly insulating parts, cables, cable glands and cable jaws.
Clean the machine thoroughiy after each session. Avoid the use of solvent, petrel a
abrasive substances which could d a m a g e insulated parts of the machine.
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fUSTK IKIMK TioamKr
SAFETY HAZARDS
Do not touch welding bead and near oreos before complete cooling.
FIRE HAZARD
Keep away from extruder materiols that c o n deterirate with heat inflammable (oil,
solvents, etc.).
7
Context: SHEETS/PIPES/FITTINGS
OTHER MATERIALS USED
RISK OF INTOXICATION
Do not weld shieets, pipes or fittings thiat contoin or hiove previously contoined toxic
substances.
Use carefully thiose chemical substances used during preparations before welding:
away from flames or hot suri'oces;
Do not smoke;
RISK OF EXPLOSION
Ventlate work place.
OTHER RISKS
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5. WORKING HYGENE
GENERAL
REFERENCES
- Directive 89/391/EEC (and successive): "Improvement of measures to protect the health and safety of
workers in the workplace" (implemented in Italy by D. L. n. 626 of 19/09/1994).
- Italian legislation D. P. R. n. 547 of 27/03/1955: Regulations for the prevention of occidents in the workplace.
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6.1 EXTRUDER
TRANSMISSION
WELDING ROD
HEATING DEVICE
MINI EXTRUDER
WELDING SHOE
Portable welding machine is composed by a mini extruder with a plasticizing unit, operated by on electric drill.
The pre-heating of parts to weld is done with o hot air blower, where the air is generated independently by the
blower.
Welding pressure is given with the non stick welding shoe directly ossembled on the extruder and corresponding
to the outlet of welding rod. According to the applicotion welding shoe c a n hove different configurotions, 1o
guorantee a correct ond homogeneous pressure.
Welding material, supplied in coils, necessor/ for welding, is positioned in the special hole to be plasticized in the
same extruder. According to diameter of rod, different quantities of material in Kg will be extruded.
6.2 PERFORMANCE
Surfaces of parts to be welded ore heoted of welding temperature by hot air which comes out from specioi
nozzle. Welding material, continuously coming out from the welder manually operated, is pressed on components
to be w e l d e d . Flux of material, pushes forward automatically the apparatus and determine welding speed. The
heoting of surfaces to be welded together must be a d a p t e d to welding speed.
10
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mane mame Hcinaiifr
A "V"-we!d
Seprate Welded
joint to be joint
welded
An angle between 45 and 90 must be chosen, according to sheet to be welded. Width of opening "B" is limited
to obout 30 mm in case of welds with oniy one welding layer, otherwise the operotor would not be able to
perform the necessary welding pressure.
To obtain a g o o d heating o n d welding, it is necessor/ to prepare^, on top pgrt,' a fissure 2 mm wide. If this
dimensin cannot be respected, it is necessory to do something, like for exarriple use some more hot air or make
another layer of weld.
B_ "Double V"-weld
Preparation of edges without fissure Preparation of edges with fissure
Joint to Joint
be welded
welded G = 10 mm
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D_ Fillet Weld
Joint to Joint
be welded
welded G = 10 mm
\\\\\
E_ Film Weld
Joint
welded
When performing this kind of weld, in order to be oble to heat o n d weld properly from one part to the other, it is
necessary to leove a littie fissure, which depends from thickness of the sheet and not smoller thon 1 mm (A).
be
welded
G = 7 mm
)/////'M Joint
welded
Surfaces which are going to be welded o n d surfaces near the orea of welding string, ore treoted ond s c r a p e d '
before welding. For this purpose oniy use suitable tools. Parts which surfaces hove been d o m o g e d by ofmosp'
or chemical agents, must b e scraped until reaching the intoct zone; this sjtuations often occurs when rpa
something
It is important to avoid using solvent detergents or detergents that might deform the material.
In order to re-equilibrate possible differences in temperature between materiols to be welded, it is necessary
stock them in working place, for a period of time necessor/ for them to b e c o m e of same characteristics, b e '
performing any welding
]2
KMTK HfUM rfORMUCT
7.INSTRUCTION F O R USE
7.1 EXTRUDER SEHING
230 V
Max length [m] <19 20-50
Cable section [mm^] 2,5 4
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If working with STARGUN CB versions it is necessory to connect the hot blower with on external oir source. Set o
pressure of about 0,4 bar.
NOTE: In order to avoid welding defects, the oir supplied must be free of humidity.
/ 220O428 /
WARNING!
STARGUN extruders ore supplied with a drill safety / 210O410 /
system. It operates in two cases: LOAD
The drill oniy starts when the working temperoture is O / 190O374 /
reached;
180O356 /
If during the use of the extruder, working
temperature is increosed or decreosed by more
than 10 C , the drill will automoticolly turn off until it
reaches the temperature set.
WORKING TEMPERATURE
At a n ambient temperature of obout 23C w e suggest to use the following plasticization temperotures:
PE 210-220 C
PP 210-220 C
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7.3 USE OF HOT AIR BLOWER
7.4 FUNCTIONALTEST
Welding test:
w e suggest to make a welding test before moking the
actual weld (follow the same procedures).
Lean welding shoe on two objects to be welded. Pre-
heot the objects for o few seconds before turning on drill.
By exercising o certain pressure, drive movement of
extruder.
Starting switch and
button to lock drill in
movement
NOTE: welding direction is determined by position of pre-
heating nozzle of welding shoe (see picture on the right). Welding
direction
15
7.5 WELDING
8. MAINTENANCE
The extruder does not need particular maintenance due to its insensitivity to external agents.
We recommend to cleon the STARGUN after ever/ use.
CLEANING
i/na
Viaxning
Do not use corros/Ve detergents
When you find dirt residual difficult to remove, be careful not to d a m a g e cables.
Clean the display of thermoregulotor with a soft cloth.
GENERAL INFORMATION
ina
Warning
Disconnect machine from electrical line before performing any maintenance intervention.
Let speciolized technicians to perform maintenance on the welder.
Before ony intervention, wait for the complete cooling of the extruder.
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9. TROUBLESHOOTINGS
ITK miMK IlCHmKI
Probiem
reference PROBABLE CAUSE REMEDY
number
1 Rod diameter is not constont If necessor/ substitute welding rod
2 Temperature prob is detective Contact Ritmo service cenfer
3 Detective thermoregulotor Contact Ritmo service center
4 Pre-heating air too hot Adjust blower temperature
5 Temperature sensor polority inverted Contact Ritmo service center
Set welding temperature ond that of
drill protection, with o mnimum volue
Safety line of temperature set is higher thon valu set for
of 30C of difference.
welding Safety T < welding T (see Cap.7_ Use
of thermoregulotor)
Check cables - C o n t a c t Ritmo serv/'ce
7 Electrical and/or connection cables disconnected or detective
center
Temperature of melting chamber is lower thon safety Wait for reaching of correct
8 temperature.
temperature set
Wait for reaching of correct
9 Heating time for material wos to short
temperature.
10 There is no tensin Restore tensin
Check electrical tensin according to
11 Electrical tensin is not correct extruder characteristics.
Check cable section (see tab. p a g e
12 Extensin cable is over heated 13)
Completely
Welding shoe or melting chamber are stopped by on external
13
object Clean the extruder
14 Faulty drill Contact Ritmo service center
Temperature prob interrupted or over its range Contact Ritmo ser/ice center
15
Temperature prob in short circuit
16 Drill brushes detective or worn out Replace
17 Shaft extruding screw detective Contact Ritmo service center
18 Detective blower Contact Ritmo ser/ice center
19 Blower resistor detective Contact Ritmo service center
20 Extruder temperoture too high Adjust extruding temperature
Reploce welding rod with another one
21 Diameter of welding rod is too small compiying with specifications given
17
R1 RESISTENZA
SCHEDA ELETTRONICA
A SPIRALE
TERMOCOPPIA
API DI C O N T R O L L O
K I I GUAINA VETR0SILIC0NL_(2 ID
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Nome nie
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230Vac 50/60HZ
REV. MODIFICA DATA FIRME LUCA VERONESE Dota 09/04/04 /
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PLASTIC Ifl/ELDING TECHNOLOGY
I
C DICHIARAZIONE DI C O N F O R M I T A 1G B MANUFACTURER'S
DEL COSTRUTTORE CONFORMITY DECLARATION
D KONFORMITATSERKLARUNG E DECLARACION D E CONFORMIDAD
DES HERSTELLERS DEL FABRICANTE
Ritmo S.p.A.
Via A. Volta, 7 - Z.l. Selve - 35033 Bresseo di Teolo (PD) - ITALIA
Tel. ++39-(0)49-990I888 Fax ++39-(0)49-9901993 - CP. 120 Bresseo di Teolo (PD)
Dictiiara ctie il prodotto di sua produzione di seguito Declares ttiat the product of its our production nanned os
dentiticato follows
STARGUN
conforme alie disposizioni delle seguenfi Direttive, is m a d e in complionce with the following directives,
Normative e prescrizioni aventi effetto di Legge: standards a n d legal regulations:
98/37/CE
89/336/CEE [92/31/CEE]
73/23/CEE [93/68/CEE]
UNI EN 292/1 (11/92)
UNI EN 292/2 (11/92)
EN 60204-1 (04/98)
La presente dichiarazione perde ogni validit in caso di This declaration becomes nuil a n d void in the event of any
modifiche apportate all'apparecchio non approvate changes being m a d e to the equipment without the written
esplicitamente e per iscrifto dal costruttore. a n d explicit manufacturer's approvol.
Die Gitigkeit der vorliegenden Erkirung ist nichtig im Falle Esta declaracin no es vlida e n caso d e aportar
von Anderungen des Gertes, die nicht ausdrckiich modificaciones a la mquina sin la expresa autorizacin
schriftiich vom Hersteller genehmigt wurden. escrita del fabricante.