Leister FUSION 3 User manual

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Leister FUSION 3
Hand-Extruder
Please read operating instructions carefully before
use and keep for further reference.
GB
OPERATING INSTRUCTIONS
Leister Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. + 41 41 662 74 74 Fax [phone] www.leister.com [email protected]
®
Welding PE and PP thermoplastics for applications in
• container engineering
• plastic fabrication
• pipeline construction
• landfill sites and abandoned polluted areas
APPLICATION

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DANGER! Danger when opening up the tool, as live com-
ponents and connections are exposed. Therefore, before
opening the tool, unplug it to ensure disconnection from
the mains.
Incorrect use of the hand extruder (e.g. overheating of the
material) can present a fire and explosion hazard, espe-
cially near combustible materials and explosive gases.
The tool must be operated with supervision. Heat can
reach combustible materials, which are out of sight.
For personal protection on building sites we strongly recom-
mend the tool be connected to a RCCB (Residual Current
Circuit Breaker) .
The voltage rating stated on the name plate of the tool
must correspond to the mains voltage and frequency.
Danger of getting burned! Do not touch exposed hot metal
parts and escaping plastizised material. Let the tool cool
down. Do not point the hot air flow and the escaping
plastizised material in the direction of people or animals.
Protect tool from dampness and wet.
FI
120
230
WARNING
CAUTION
TECHNICAL DATA
Voltage V~ 230
Power consumption W 3500
Frequency Hz 50/60
Air flow (20°C) l/min ca. 300
Air temperature °C max. 350
Plasticizer temperature °C max. 280
Welding output kg/h ø 3 PE 1.6 - 2.3 ø 3 PP 1.3 - 2.0
(Average values at 50 Hz) ø 4 PE 2.0 - 3.5 ø 4 PP 1.5 - 2.7
Welding rod mm ø 3 / ø 4 ± 0.2 (in accordance with DVS 2211)
Size L × W × Hmm670 ×90 ×180 (without welding shoe)
Weight kg 7.2 with 3m cable
Mark of conformity ¬
Mark of approval †
Certification scheme CCA
Protection class II ¶
Line/mains voltage cannot be switched over

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OPERATING Leister FUSION 3
Description of tool
FUSION 3 General view
FUSION 3 / Tool rest
1. Hot air blower switch
2. Air temperature potentiometer
3. Locking device
4. Drive on/off switch
5. Welding shoe
6. Welding rod opening
7. Extrusion rate regulation potentiometer
8. Tool rest
9. Handle
10. Tool handle
11. Drive unit
12. Hot air blower
13. Mains cable
14. Air slide
5
6
3
7
2
1
4
11
10
12
13
9
8
14

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Preparation for welding
• The tool rest (8) or handle (9) can alternatively be mounted left of right of the tool.
• When using an extension cable, take care to ensure the minimum cable cross-
section:
OPERATING Leister FUSION 3
Length Minimum cross-section (at ~230V)
Extension cables must be approved for the place of work (e.g. outdoors) and
labelled accordingly.
• If a generator is used to supply electricity, the rated power of the generator must
be 2x the rated power of the hand extruder
The hand extruder must not be operated in inflammable environments or
where explosion hazards exist. Ensure stable positioning during operation.
The connecting cable and the welding rod must remain unimpeded and
must not hinder the user or others during operation.
Switching on
• Connect the hand extruder to the mains supply.
• Switch on the tool at the hot air blower switch (1).
• Adjust the hot air temperature at the air temperature potentiometer (2).
• The operating temperature is reached after approximately 10 minutes.
Starting protection
The tool is equipped with current overload protection. The drive switches off auto-
matically if current consumption is too high. The drive can for example not be star-
ted, or only for a brief time, if the material in the screw is insufficiently plastizised.
Overheating protection
If the drive overheats as a result of external influences or if the melting temperature
of the material in the screw is too low, the internal temperature protection switches
off the drive. The overheating protection switches on again automatically once the
drive has cooled down.
[m] [mm2]
2.5
4.0
20-50
up to 19

OPERATING Leister FUSION 3
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Starting the welding process
• Fit the required welding shoe (5) according to the paragraph "Change of welding
shoe”.
• Welding can begin once the operating temperature has been attained. Operate
the drive on/off switch (4) for this purpose. Operate the tool only when feeding
welding rod.
• Feed welding rod of 3 or 4 mm diameter into the welding rod opening (6) and
allow a small amount plastizised material to escape.
CAUTION! Never feed welding rod into both welding rod openings at the
same time! (see "Starting protection").
• The extrusion rate can be changed using the extrusion rate regulation potentio-
meter (7) dependent on the seam geometry and the choice of material.
• Interrupt material extrusion using the drive on/off switch (4).
• Direct the pre-heating nozzle (14) 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 drive on/off
switch (4).
• Carry out test welding and analyse.
• Set temperature with potentiometer (2) or air slide. Adjust extrusion quantity as
required.
• In case of a prolonged welding process, the drive on/off switch (4) can be held in
the active state with the locking device (3).
• The welding rod is pulled in through the welding rod opening (6) automatically
after starting. The welding rod pull - in must not be impeded.
Switching off
• Release the locking device (3) by briefly pressing the drive on/off switch (4) 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 (see pg. 3, "FUSION 3 / Tool rest").
Use a fireproof base. The hot air jet must not be directed towards persons
and objects.
• Adjust the air temperature potentiometer (2) to "0". Let the tool cool down for a few
minutes.
• Switch off at the hot air blower switch (1).
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 devices with the appropriate
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.

OPERATING Leister FUSION 3
Change of welding shoe
• The welding shoe must only be changed when the tool has attained its operating
temperature. Work with temperature resistant gloves only.
Danger of getting burned!
• Switch off the hot tool and disconnect it from the mains supply.
•Remove the welding shoe holder (15) by loosening the set screws for the welding
shoe holder (16) from the extruder nozzle (17).
• Clean the extruder nozzle (17) each time the welding shoe is replaced and remove
any welding deposits.
• Attach an appropriate welding shoe holder (15).
• The pointing of the welding shoe (5) (tool angle to the welding seam) can be
chosen freely.
• The welding shoe (5) can be taken off the welding shoe holder (15) by loosening
the set screws for the welding shoe (18) (e.g. for reworking).
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5. Welding shoe
15. Welding shoe holder
16. Set screw for welding
shoe holder
17. Extruder nozzle
18. Set screw for welding
shoe
19. Pre - heating nozzle
Detail welding shoe
5
16
16
19
15
18
17

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BA FUSION 3 / 11/2004
• Only Leister accessories must be used.
• In case of soiling clean the air inlet on the hot air blower with a brush.
• Clean the extruder nozzle (17) each time the welding shoe is replaced and
remove any welding deposits.
• Check power supply cord (1) and plug for electrical and mechanical damage.
• At minimal length of the carbon brushes the motor switches off automatically.
The tool should be checked by your Service Centre.
The carbon brushes will last approx. 1000 hours running time.
• Have the condition of the carbon brushes checked by your Service Centre after
approx. 200 hours of running time.
• Repairs should only be carried out by authorized Leister Service Centres. They
guarantee a specialised and reliable Repair Service within 24 hours using original
spare parts in accordance with the circuit diagram and spare parts list.
• Guarantee and liability are in accordance with the guarantee certificate as well
as with the currently valid general conditions of business and terms of delivery.
• Leister Process Technologies rejects any guarantee claims for tools which are not in
their original condition. The tools must never be altered or changed.
Technical data and specifications are subject to change without prior notice.
Your authorized Service Centre is:
GUARANTEE AND LIABILITY
SERVICE AND REPAIRS
MAINTENANCE
ACCESSORIES
®
Leister Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. + 41 41 662 74 74 Fax [phone] www.leister.com [email protected]

Service Record Leister FUSION 3
This document should be kept up to date during repair or servicing by the
authorized Leister Service Centre. This document should be in the possession of
the owner of the equipment.
Technical data
Order No.
Serial No.
Rated voltage V
Rated capacity W
Sale date
Service
1. Date Service Centre Signature
2. Date Service Centre Signature
3. Date Service Centre Signature
4. Date Service Centre Signature
5. Date Service Centre Signature
6. Date Service Centre Signature
Repair
1. Date Service Centre Signature
2. Date Service Centre Signature
3. Date Service Centre Signature
®
Leister Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. + 41 41 662 74 74 Fax [phone] www.leister.com [email protected]
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