Leister FUSION 3C User manual

FUSION
2/3C/3
®
Fusion 2
Fusion 3C
Fusion 3

Please read operating instructions carefully before
use and keep for further reference.
Operating Instructions (Translation of the original operating instructions)
Leister FUSION 2/3C/3
Extrusion Welder
GB
DANGER!
Danger when opening up the tool, as live components and connections are
exposed. Therefore, before opening it, unplug the tool to ensure disconnection
from the mains. Electronically conductive material (eg PE-EL) must not be welded.
Incorrect use of the hand extruder (eg overheating of the
material) can present a
fire and explosion hazard, especially near combustible materials and explosive
gases.
Danger – can cause burns! Do not touch bare metal parts and emerging
material while hot. Allow the device to cool. Do not direct stream of hot air or
emerging material towards people or animals.
Warning
The tool must be operated under supervision. Heat can ignite flammable
materials which are not in view.The machine may only be used by qualified
specialists or under their supervision. Children are not authorized to use
this machine.
For personal protection on building sites we strongly recommend the tool be
connected to a RCCB (Residual Current Circuit Breaker) .
Protect tool from damp and wet.
FI
Caution
Application
Welding PE and PP thermoplastics for applications in
• container engineering • pipeline construction
• plastic fabrication • landfill sites and abandoned polluted areas
The voltage rating stated on the tool must correspond to the mains voltage.
If power failure occurs, the hot air blower switch and drive must be switched o
(release locking device).
120
230

Conformity
Leister Technologies AG, Galileo-Strasse 10, CH-6056 Kaegiswil/Switzerland confirms that these
products, in the versions as brought into circulation through us, fulfil the requirements of the following EC
directives.
EC directive(s): 2006/42, 2011/65, 2014/30, 2014/35
Harmonized Standards: EN ISO 12100, EN 55014-1, EN 55014-2, EN 61000-6-2, EN 61000-3-2,
EN 61000-3-3, EN 62233, EN 60335-1, EN 60335-2-45, EN 50581
Kaegiswil, 31.10.2018
Bruno von Wyl, CTO Christoph Baumgartner, GM
Disposal
Electrical equipment, accessories and packaging should be recycled in an environmentally friendly
way. For EU countries only: Do not dispose of electrical equipment with household refuse!
Technical Data
Technical data and specifications are subject to change without prior notice.
FUSION 2
Ø4mm FUSION 3C
Ø3 /Ø 4mm FUSION 3C Ø4 /Ø 5mm FUSION 3 Ø3 /Ø 4mm FUSION 3 Ø4 /Ø 5mm
Welding rod mm
(in accordance with DVS 2211) Ø4
± 0.3 Ø3 /Ø4 ± 0.3 Ø4 /Ø5 ± 0.3 Ø3 /Ø4 ± 0.3 Ø4 /Ø5 ± 0.3
Ø3; Welding output [kg/h]
(Average values at 50 Hz)
PE 2.0 – 2.5
PP 1.8–2.3
PE 2.0 – 2.5
PP 1.8–2.3
Ø4; Welding output [kg/h]
(Average values at 50 Hz)
PE 1.3–1.8
PP 1.3–1.8
PE 2.7 – 3.6
PP 2.5 – 3.4
PE 2.1–2.6
PP 1.8–2.4
PE 2.7 – 3.6
PP 2.5 – 3.4
PE 2.1–2.6
PP 1.8–2.4
Ø5; Welding output [kg/h]
(Average values at 50 Hz)
PE 2.7–3.6
PP 2.5–3.4
PE 2.7–3.6
PP 2.5–3.4
FUSION 2 FUSION 3C FUSION 3
Voltage V~
Mains voltage is not reversible 230 220 120 230 220 230
Power consumption W 2800 2600 2800 3200 3000 3500
Frequency Hz 50/60 60 50/60 50/60 60 50/60
Air flow (20°C) l/min ca. 300 ca. 300 ca. 300
Air temperature °C max. 340 max. 350 max. 350
Plasticizer temperature °C max. 300 max. 320 max. 320
Vibration acceleration ah (m/s2)< 2.5 (K = 1.5 m/s2)< 2.5 (K = 1.5 m/s2)< 2.5 (K = 1.5 m/s2)
Size L ×W ×H mm
(without welding shoe) 450×98×225 588×98×225 690×98×187
Weight kg
without Power supply cord
5.9 6.9 7.2
Mark of conformity
/ /
Protection class II

Description of tool
1 Hot air blower switch
2 Air temperature potentiometer
3 Locking device drive on/o switch
4 Drive on/o switch
5 Welding shoe
6Welding rod opening
7Extrusion rate regulation potentiometer
8 Tool rest
9Handle
10 Tool handle
11 Drive unit
12 Hot air blower
13 Power supply cord
14 Air slide
15 Air inlet
16 Air hose
5
9
6
3
7
2
1
4
11
10
12 13 15
14
16
FUSION 3
5
611
12
15
13
3
7
2
4
10
8
116
8
9
FUSION 2
FUSION 3C
9
15

• The tool rest (8) or handle (9) can alternatively be mounted left of right of the tool.
• Before putting into operation, check power supply cord (13) and connector as well as extension cable for
electrical and mechanical damages.
• When using an extension cable, take care to ensure the minimum cable cross-section:
•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 ha-
zards 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.
Preparation for welding
Length
[m]
Minimum cross-section (at ~230V)
[mm2]
up to 19 2.5
20-50 4.0
Starting protection
The tool is equipped with current overload protection. The drive switches o automatically if current consumption
is too high. The drive can for example not be started, 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 o the drive. The overheating protection switches on
again automatically once the drive has cooled down.
• 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
Switching on
Welding rod, PE / PP Ø3 or Ø4mm
– Only use for the hand extruder without
labeling (see picture A).
Welding rod, PE / PP Ø4 or Ø 5mm
– Only use for the hand extruder with
labeling (see picture B).
Welding rod
Picture A
Picture B

Starting the welding process
• Fit the required welding shoe (5) according to the paragraph „Change of welding shoe” (see page 15).
• Welding can begin once the operating temperature has been attained. Operate the drive on/o switch (4) for
this purpose. Operate the tool only when feeding welding rod.
• Feed welding rod into the welding rod opening (6) (see chapter welding rod) and allow a small amount plasti-
zised material to escape.
CAUTION! Never feed welding rod into both welding rod openings at the same time! (see page
13 «Starting protection»).
The welding rod fed must therefore be clean and dry.
• The extrusion rate can be changed using the extrusion rate regulation potentiometer (7) dependent on the
seam geometry and the choice of material.
• Interrupt material extrusion using the drive on/o switch (4).
• Direct the pre-heating nozzle (21) 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/o switch (4).
• Carry out test welding and analyse.
• Adjust the hot air temperature using the air temperature potentiometer (2) and the extrusion rate with the
extrusion rate regulation potentiometer (7) as required.
• In case of a prolonged welding process, the drive on/o 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.
• Release the locking device (3) by briefly pressing the drive on/o
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 (8) .
Use a fireproof base. The hot air jet must not be directed towards
persons and objects.
•The air temperature potentiometer (2) to „0“. Let the tool cool down.
•Switch o at the hot air blower switch (1).
Switching o
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 car-
rying 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.
8
21

5 Welding shoe
17 Welding shoe holder
18 Clamp screws
19 Extruder nozzle
20 Fastening screw
21 Pre - heating nozzle
Danger of getting burned! Work with temperature resistant gloves only.
•The welding shoe must only be changed when the tool has attained its operating temperature.
Changing the welding shoe
• Disassembly
– Remove the welding shoe (5) with the welding shoe holder (17) by unfastening the clamp screws (18)
from the extruder nozzle (19).
– Every time the welding shoe is changed, clean the extruder nozzle (19) of welding residue and make sure
that it is screwed in tightly.
– Remove welding shoe (5) from the welding shoe holder (17) by unfastening the fastening screws (20).
• Assembly
– Fasten a welding shoe (5), appropriate to the welding seam, onto the welding shoe holder (17) with
fastening screws (20).
– The welding shoe (5) and welding shoe holder (17) must be tightened properly with the clamp screws (18)
• The welding shoe (5) can be turned infinitely to
the desired welding direction by loosening the
clamp screws (18).
• The clamp screws (18) must be tightened well
again afterwards.
Switch o the hot tool and disconnect it from the mains supply.
Welding direction
18
5
5
21
19
17
18
18
20
5
5
518

Accessoires
• Only Leister accessories must be used.
Maintenance
•In case of soiling clean the air inlet (15) on the hot air blower with a brush.
• Clean the extruder nozzle (19) each time the welding shoe is replaced and remove any welding deposits (see page 15).
• Check power supply cord and plug for electrical and mechanical damage.
•Regularly clean the air hose (16).
Service and Repairs
• Have the state of the carbon brushes of the drive and hot air blower checked by your service centre after
ca. 250 hours of operation. The drive and the hot air blower switch off automatically once the minimum
carbon length has been reached.
Operating time; Drive ca. 300 hours (brushes)
Hot air blowers ca. 1000 hours (brushes)
• 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.
Warranty
• For this tool, we generally provide a warranty in accordance with the statutory / country-specific regulations from
the date of purchase (verified by invoice or delivery document). Damage that has occurred will be corrected
by replacement or repair. Heating elements are excluded from this warranty.
• Additional claims shall be excluded, subject to statutory regulations.
• Damage caused by normal wear, overloading or improper handling is excluded from the guarantee.
• Guarantee claims will be rejected for tools that have been altered or changed by the purchaser.

®
Your authorised Service Centre is:
© Copyright by Leister
Allied Power Tools
12/ 76 Rushdale St, Knoxfield VIC 3180 Australia
T: + 61 3 9764 2911
E: [email protected]
W: www.alliedpowertools.com.au