Leister FUSION 1 User manual

Leister Technologies AG
Galileo-Strasse 10
CH-6056 Kaegiswil/Switzerland
Tel. [phone]
Fax [phone]
www.leister.com
[email protected]
FUSION 1
EN

EN
English Operating Instructions 4

3
EN
English Operating instructions
Contents
1.
Important safety instructions ...................................................................................................................4
1.1 Intended use ....................................................................................................................................5
1.2 Non-intended use .............................................................................................................................5
1.3 Safety Instructions ............................................................................................................................5
2.
Technical data ..........................................................................................................................................5
3.
Transport .................................................................................................................................................6
4.
Your FUSION 1..........................................................................................................................................6
4.1 Type plate and identification .............................................................................................................6
4.2 Scope of delivery (standard equipment in the case)............................................................................6
4.3 Overview of device parts ..................................................................................................................7
5.Preparation for welding...........................................................................................................................8
5.1 Welding rod.....................................................................................................................................8
5.2 Switching on....................................................................................................................................8
5.3 Starting the welding process.............................................................................................................9
5.4 Switching off ...................................................................................................................................9
5.5 Checking the temperature of the extrudate and the prewarming air...................................................10
5.6 Replacing the welding shoe.............................................................................................................10
5.7 Welding direction............................................................................................................................10
6.
LCD display.............................................................................................................................................11
6.1 Status display symbols....................................................................................................................11
6.2 Working display ..............................................................................................................................11
7.
Setup menu ............................................................................................................................................13
7.1 Fixing the setpoint temperature setting.............................................................................................14
7.2 Switching off the air supply..............................................................................................................14
8.Quick Reference Guide FUSION 1 ...........................................................................................................15
8.1 Switching on/Starting......................................................................................................................15
8.2 Switching off ..................................................................................................................................15
9.
Warnings and error messages................................................................................................................15
9.1 LCD display for warnings and error messages...................................................................................15
9.2 LED light displays for warnings and error messages..........................................................................16
10.
LED light displays for warnings and error messages...........................................................................17
11.
Accessories ..........................................................................................................................................17
12.
Maintenance.........................................................................................................................................17
13.
Service and repair ................................................................................................................................17
14.
Training.................................................................................................................................................18
15.
Warranty ...............................................................................................................................................18
16.
Other applicable documents.................................................................................................................18
17.
Conformity............................................................................................................................................18
18.
Disposal................................................................................................................................................18

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Operating instructions (translation of original operating instructions)
EN
LEISTER FUSION 1
manual extrusion welder
Read through the operating instructions before commissioning for the first time.
Always store these operating instructions with the device.
Do not pass the device on to anyone else without the operating instructions.
In addition to the safety instructions contained in the individual chapters of these operating instructions, the
following provisions must also be followed.
1. Important safety instructions
Congratulations on your purchase of the FUSION 1.
You have chosen a first-class hot-air extrusion welder.
It has been developed and produced in accordance with the very latest standards of technology in the plas-
tics-processing industry. It has also been manufactured using high-quality materials.
Warning
FI
Caution
Danger to life
Disconnect the power plug from the socket before opening the device, as
live components and connections will be exposed.
Danger of fire and explosion
If the device is used improperly, there will be a danger of fire and explosion (e.g., due
to the material overheating), particularly in the vicinity of flammable materials and
explosive gases.
Risk of burning
Do not touch exposed metal parts or escaping material while they are hot. The
device should always be allowed to cool down first. Do not point the hot air flow
or escaping material at people or animals.
If the device is being used on construction sites, an FI protective switch must be
used to protect site personnel.
The nominal voltage specified on the device must match the local line voltage.
If the line voltage fails, then the main switch and the drive must be switched o
(extend hot-air blower).
Protect the device from moisture and wet conditions.
The device may only be used under supervision. Waste heat can come into
contact with flammable materials that are not in view.
The device may only be operated by trained specialists or under their supervi-
sion. Children are not permitted to operate the device under any circumstances.

5
The FUSION 1 is designed for professional welding of thermoplastic materials made from PE and PP in the fields
of
• container construction
• pipeline construction
• apparatus construction
• landfill and contaminated sites
• repairs
Use only original Leister spare parts and accessories; otherwise, any warranty or guarantee claims will be invali-
dated.
Welding processes and types of materials
• Welding thermoplastic materials (PE, PP)
Any other use or any use beyond the type of use described is deemed non-intended use.
Subject to change without prior notice.
1.1 Intended use
1.2 Non-intended use
FUSION 1
120 V
FUSION 1
220 V
FUSION 1
220 V / 220 – 240 V
Welding rod
(in acc. with DVS 2211)
Ø mm Ø 3 / Ø 4 ± 0.3 Ø 3 / Ø 4 ± 0.3
Ø 3; output
(mean values at 50 Hz)
kg/ h PE 0.260 – 0.480
PP 0.330 – 0.540
PE 0.260 – 0.450
PP 0.330 – 0.500
Ø 4; output
(mean values at 50 Hz)
kg/ h PE 0.330 – 0.800
PP 0.350 – 0.830
PE 0.330 – 0.750
PP 0.350 – 0.760
The safety instructions for the device can be found in the section on “Safety Instructions – Automatic Welders/
Extrusion Welders/Welding Machines” in the document provided.
You can also find this document in the operating instructions on our website.
1.3 Safety Instructions
2. Technical data
FUSION 1
120 V
FUSION 1
220 V
FUSION 1
220 – 240 V
Nominal voltage V~ 120 220 230
Nominal output W 1450 1100 1200
Frequency Hz 50 / 60 60 50 / 60
Air temperature °C Approx. 180 – 320
Air volume (20 °C) % Approx. 230
Plasticizing temperature °C max. 280
Emission level LpA (dB) < 70 dB (K = 3 dB)
Vibration level ah(m/s2)< 2.5 (K = 1.5 m/s2)
Dimensions (L × W × H) mm 436 × 92 × 236
Weight kg 3.4
Conformity marking /
Protection class II

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Use only the transport box included in the scope of delivery for transporting the FUSION 1.
The hot-air protective pipe (9) must be allowed to cool down prior to trans-
port.
Never store flammable materials (such as plastic, wood, or paper) in the
transport box.
3. Transport
4. Your FUSION 1
4.1 Type plate and identification
4.2 Scope of delivery (standard equipment in the case)
Example:
The model designation and serial number are indicated on the type plate (5) of your FUSION 1.
Please enter this information in your operating instructions and always reference it when addressing inquiries
to our representatives or authorized Leister Service Centers.
Model:..............................................................................................................................................................
Serial no.:.........................................................................................................................................................
1 x FUSION 1
1 x motor/blower filter set
1 x CL 14 welding shoe
1 x hexagon wrench key, size 3
1 x hexagon wrench key, size 5
1 x original operating instructions
1 x translation of original operating instructions

7
4.3 Overview of device parts
1. Drive motor/blower air inlet
2. Welding rod openings
3. Output regulation potentiometer
4. Handle (can be mounted)
5. Type plate with model designation and series
marking
6. Power cord
7. Hanging hook (optional)
8. Welding shoe
9. Hot-air protective pipe
10. Air temperature potentiometer
11. LCD display
12. Hot-air blower switch
13. Thread for mounting handle
14. LED light, status display
15. On/o drive switch
16. Locking screw (for mounting handle)
1
1098 11
12
5
131415
2
3
6
4
16
4
7
2

8
• Mount the handle (4) on the FUSION 1 (using locking nut 13) if required. Observe the maximum tightening
torque of 4 Nm.
• Prior to commissioning, check the power cord (6), the plug, and the extension cable for electrical and me-
chanical damage.
• The minimum cross-section must be observed if an extension cable is being used:
Length
[m]
Minimum cross-section (at ~230 V)
[mm2]
Up to 19 2.5
20 – 50 4.0
• Extension cables must be authorized for the utilization site (e.g., outdoors) and marked accordingly.
• When a power generator is used as an energy supply, the following applies for its nominal output: 2 x hand
extruder nominal output.
The FUSION 1 must not be used in areas with explosion and/or ignition
hazards. Ensure that you are in a stable position while working. The connection cable and
welding rod must be able to move freely and must not hinder the user or third parties while
working.
5. Preparation for welding
5.1 Welding rod
5.2 Switching on
Use only a PE/PP welding rod with Ø 3 or Ø 4 mm for the FUSION 1.
• Connect the FUSION 1 to the electrical line supply.
• Switch on the FUSION 1 using the hot-air blower switch (12).
• Use the air temperature (10) potentiometer to adjust the hot-air temperature. The set value appears on the
LCD display (11).
• After around 5 minutes, the operating temperature is reached and the LED (14) lights up.
Starting protection
The FUSION 1 is equipped with drive overload protection. If the speed becomes too low, the drive
switches o automatically. For example, the drive cannot be started or can only be started for a short time if
the material is insuciently plasticized in the screw. Reheating then takes place for another 2 minutes.
A countdown counter appears on the status display area of the LCD display (11).

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5.4 Switching off
• Press the on/o drive switch (15).
• Remove the welding material from the welding shoe so the welding shoe is not damaged the next time the
device is started.
• The FUSION 1 may now be stored on its side.
• Set the air temperature potentiometer (10) to “0”. Allow the device to cool down.
• Switch o the hot-air blower switch (12).
The hot air flow must not be pointed at
people, animals, or objects
Use a fireproof support
Overheating protection
If the drive is overheated due to external influences or if the melting temperature of the material in the screw is
too low,
the internal temperature protection will switch the drive o. Er 0400 will appear on the display (11). Disconnect
the FUSION 1 from the line supply and allow it to cool down.
5.3 Starting the welding process
If necessary, mount the appropriate welding shoe (8) (see Chapter 5.6, “Replacing the welding shoe”).
• Once the operating temperature has been reached, welding can start. To do this, press the on/o drive switch
(15). Always operate the FUSION 1 with the welding rod inserted.
• Insert the welding rod (Chapter 5.1, “Welding rod”) into one of the welding rod openings (2) and allow some
material to escape.
CAUTION: Never insert the welding rod into both welding rod openings at the same time.
• The welding rod must be clean and dry when it is inserted.
• The output can be changed on the basis of the rod geometry and choice of material using the output regula-
tion potentiometer (3). The set speed appears in a bar graph on the display (11).
• Pause the delivery of material using the on/o drive switch (15).
• Point the prewarming nozzle (17) at the area to be welded.
• Prewarm the area to be welded with oscillating movements.
• Place the FUSION 1 on the prepared area to be welded and press the on/o drive switch (15).
• Create and analyze a sample weld.
• Adjust the hot-air temperature as necessary using the air temperature potentiometer (10) and the output
volume as necessary using the output regulation potentiometer (3).
• The welding rod is automatically drawn through the welding rod opening (2) after starting.
It must be possible to insert the rod without resistance.
17

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5.5 Checking the temperature of the extrudate and the prewarming air
• The temperature of the extrudate and the hot air flow must be checked regularly during extended periods of
welding work:
Fast-indicating electronic temperature probes with suitable temperature sensors must be used for this purpose.
You must identify the highest temperature in the hot air flow between the nozzle outlet level and a depth of 5
mm. During extrudate measurement, the measurement sensor in the welding shoe must be inserted into the
middle of the strand.
8 Welding shoe
18 Clamping screws
19 Prewarming nozzle
20 Welding shoe holder
21 Fastening screws
22 Extruder nozzle
Risk of burning
Always work with temperature-resistant gloves.
5.6 Replacing the welding shoe
• The welding shoe must be replaced while the device is warm.
5.7 Welding direction
• Detaching the clamping screws (18) allows the
welding shoe (8) to be rotated freely to the required
welding direction.
• The clamping screws (18) must then be retightened
well again.
• Removal
– Remove the welding shoe (8) with the welding shoe holder (20) by detaching the clamping screws (18)
from the extruder nozzle (22).
– Every time the welding shoe is replaced, clean the extruder nozzle (22) by removing any welding residue from
it and make sure that it is screwed in tightly. Note: left-hand thread
– Remove the welding shoe (8) by detaching the fastening screws (21) from the welding shoe holder (20).
• Mounting
– Mount a welding shoe (8) that is adapted for the welding rod on the welding shoe holder (20) using fas-
tening screws (21).
– The welding shoe (8) and welding shoe holder (20) must be tightened well using the clamping screws
(18).
Switch o the FUSION 1 while it is warm and disconnect it from the electrical line supply.
8
19
20
21 22
18