Noztek fusionX User manual

USER MANUAL
© Noztek.com 2021. All rights reserved

1. a IN THE BOX
b DIAGRAM
c WARRANTY
d SAFETY
e TECH SPECS
2. a POWER SWITCH AND START UP
b TOUCH SCREEN INTERFACE OPERATION
3. a CONNECTING fusionX TO YOUR COMPUTER
b CLEANING
c OPENING THE BARREL
d REMOVING THE BARREL FROM THE BASE
e CHANGING THE NOZZLE
4. a MIXING/BLENDING
b LUBRICATION
c BARRREL JAM
d COOLDOWN
5. a CONTACT NOZTEK
1. a IN THE BOX
• fusionX - fully assembled
• Hopper weight
- This can be used to press the material in the hopper into the feed section
of the screw and is especially useful when using light powdered materials
• Torque wrench
- Used to tighten and loosen the bolts on the front and top of the block. Make sure the wrench
is set to 24Nm when tightening the top bolts and 18Nm for the front nozzle holder bolts.
• 4 x M8 35mm grub screws
(These are inserted into all four corners of the block, tightened
in turn to split the block apart for cleaning)
• 4 x M4 40mm bolts
- Used to remove the mixing blades)
• Copper grease
- When reassembling the block it is advisable to coat the thread with this anti
seize copper solution. Also when swapping or replacing the nozzle, coat the thread with the
copper slip.
• FusionX protective cover
- To be used when dismantling the block to protect the chassis from being scratched.
CONTENTS

1. b DIAGRAMS
Touch
Screen
Hopper
Thermocouple 1
Barrel
Nozzle
Quick Power-O
Power Socket
Power Switch
USB Connection
24cm67.5cm
33cm
Screw
Blending Blades
Heat Sink
Barrel (top)
Barrel (bottom)

1. c WARRANTY
• Equipment manufactured by Noztek carries the
standard machine tool guarantee of freedom
from defects in workmanship and material for one
year from date of shipment.
• TO INSURE THAT YOUR WARRANTY IS HELD IN
EFFECT, PROPER OPERATION PROCEDURES MUST
BE OBSERVED.
• NOTE: READ THE SAFETY PRECAUTIONS BEFORE
OPERATING THIS MACHINE.
1. d SAFETY
1. Carefully read the instruction manual.
2. Learn the proper, safe use and limitations of the
equipment.
3. DO NOT operate or use this equipment for any
purpose other than its intended use.
4. DO NOT modify this equipment.
5. DO NOT perform adjustments or maintenance
while system is operating or energize
6. DO NOT clean the equipment with ammable
solvents.
7. DO NOT wash down the equipment with water.
This could cause an electrical hazard.
8. DO NOT probe into extruder vent with the ma-
chine running. Never Use a metal probe in
the vent area. The screw may shear the probe,
causing extensive damage to the barrel
and screw. A wooden probe is recommended.
9. DO wear a face shield, insulated gloves when
operating and when in close proximity to
the extruder during operation. These protective
items must also be worn when adjusting
the die, cleaning the screw, etc. The extruder tem-
peratures are extremely hot and failing to
protect yourself may cause serious injury.
10. The feed hopper MUST be installed on the ex-
truder feed section at all times when in operation
11. NEVER put hands in the feed section or vent to
remove material.
13. DO NOT switch on the motor until the recom-
mended temperature has been reached.
1. e TECH SPECS
- 1000w rectangular ceramic heater (max tempera-
ture 500c)
- DAK Nozzle Band Heater 35D 25L 230-250V max
.210W (max temperature 450c)
- Auto switching 110v/220v Traco power supply
24V 10 amp
- Precision machined solid stainless steel barrel
- DC motor 17 RPM – 17 Nm torque
- Precision turned bespoke stainless steel mixing
screw
- 7 inch TFT touch screen
- Stainless steel micro hopper (with hopper weight)
- 1.75mm and 3mm stainless steel nozzles
- 3 sets ( 6 in total) of hardened steel cutting blades
10mm, 3mm and 1mm
2. a POWER SWITCH AND START UP
To begin, rst cuse the power switch on the side of
the machine to power up.
Powering up will take just a few moments, after
which you’ll use the touch screen to set all extrud-
ing parameters and set the machine to begin.

1 - HOME
This screen shows all your settings, and appears red
to begin with as nothing has been set. As you dene
settings, the corresponding boxes will turn green to
show that they are ready to go.
Press MENU to begin.
2 - MENU
This is where you control the settings. Use the three
‘set’ buttons to control the respective settings for the
run.
3 - SET TEMPERATURES
Here you can set the mixing temperature and the extrud-
ing temperature. Use the slider and/or the + and - but-
tons to control the settings.
You are able to set two temperatures, the extruding
temperature and the mixing temperataure. The warm-
up heater at the base of the barrel is for reference
ownly
Pressing SET will take you to the WARM UP screen
4 - WARM-UP
is screen has a timer to allow the machine to warm to
the correct temperature. You will not be able to escape
this screen until the warm-up is complete, at which time,
you will return to the HOME screen.
2. b TOUCH SCREEN INTERFACE

5 - SET SPEED
This sets your extrusion speed. Maximum speed is 17rpm
6 - SET TIMER
This represents the time you want to extrude the mate-
rial.
The machine will run for this set time once you have
switched on the motor. If no value is entered here, the
machine will run until you manually end the run your-
self.
7 - HOME (READY)
When you see that all boxes are green, you are ready to
extrude. Press the Motor box to begin.
Use the FAN ON/OFF toggle in the bottom right corner
to activate/deactivate the fan assistance at any time (fan
located under the heat-sink at the centre of the machine
(see diagram).
Press ‘start cool down’ when you are nished, this will
begin the shut-down process.
7 - COOL DOWN
This screen will show whilst the cool down is happening.
The preset is 62 minutes
Cancelling the cool down timer wll take you back to your
extrusion run.
Please run the full cool down beef before switching o
the machine.

3.a CONNECTING fusionX TO YOUR COMPUTER
1 - Download the Noztek Controller software
from our website - https://www.noztek.com/soft-
ware-download/
2 - Connect the fusionX machine to the laptop with
a USB cable.
3 - Once the cable is connected and the controller
software has been opened on the laptop, you can
control the settings from the laptop interface
- To change temperature or the motor settings.
enter the value you want in the relevant eld using
the keyboard and then press“Set”.
- To activate or deactivate the fanpress the “ON/
OFF” button next to “Fan state”.
- To visualize the data on a graph, go to Display >
Display data on graph.
- To export you data just click on“Export data to
.csv” on the bottom right of the window.
For more in depth guidance on the controller soft-
ware, please nd the dedicated controller software
manual in the manuals section of our website
3. b CLEANING
Make sure that most of the material has been ex-
truded from the barrel before cleaaning
When cleaning in situ, please use the fusionX pro-
tective cover provided to protect the main body
of the machine from any chemicals used in the
cleaning process.
The cover has been custom made for the machine,
please place each tab between the cables and
xtures underneath the barrel and the motor (back
lays down rst). Use the velcro to keep the cover
pieces in place.
3.c OPENING THE BARREL
These instructions are for cleaning the barrel in-si-
tu. If you would like to remove it and clean away
from the base, please follow instructions to do so
in the next section.
1. Unscrew the 4 bolts connecting the motor
casing, pull motor casing back or remove.
2. Unscrew the two front and two rear grub
screws connecting the couplings to the screw and
pull this back until the coupling has disengaged
from the screw spindle.
3. Remove both thermocouple couplings (one
connected to the nozzle and the other on top of
the block).
4. Remove the front nozzle and unbolt the
front nozzle bracket (5 x M8 bolts),
5. Remove the 10 M10 bolts on the top of the
block
6. Located on the top block are four M5 allan
bolts (‘block splitters’). Screw down each corner 5
or 6 turns and continue until the top block splits
apart from the bottom section.
7. To remove the screw gently lift the front tip
and the screw should come loose from the bottom
barrel block (Depending on the type of material
debris in the barrel a solvent may be required to
assist the removal process).

8. The cutting blades can be removed by lev-
ering each blade individually out of it’s slot. If this
proves dicult, there are two threaded holes on
each end. Use a 25mm M3 bolt to screw down and
lift each side.
*Make sure both at surfaces of the barrel are com-
pletely clean before reassembly.*
Copper grease (provided) : When reassembling the
block it is advisable to coat the thread with this
anti-seize copper solution.
Please also make sure both block surfaces are per-
fectly clean. Place the top on the lower bleck and
bolt on the nozzle holder in the front (nger tight),
this will align both sections.Then tighten all eight
M8 bolts on the top of the block using the torque
wrench provided (set to 24Nm). and tighten the
nozzle holder again at 24 Nm.
3. d REMOVING BARREL FROM THE BASE
If you are using solvents to clean the barrel, you
will want to remove the barrel from the base of the
machine. You can do this by following the steps
below. Please refer to the diagram on page 3.
Please rst perform steps 1-4 as above. As you’ll
be opening the barrel eventually, it’s recomended
that you also loosen the bolts in step 5 while it’s all
attached to the base as they are quite tight and the
base acts as a stabalising jig.
Next, unscrew the bolts below the barrel, above
the barrel feet, highlighted in the diagram below.
3. e CHANGING THE NOZZLE
Before attempting this operation please use in-
sulated gloves. To switch between nozzle sizes to
heat up the unit to175c. Unscrew the nozzle, clean
o any excess plastic from the internal threads,
then screw on new nozzle
4. a BLENDING/MIXING
All our fusionX extruder’s are shipped with three
sets of hardened cutting blades. Usually these are
placed in sequence within the block. For example
the 10mm blade would be rst in line, then the
3mm and lastly the 1mm blade. This ensures a
gradual hot melt mixing set up, so by the time the
material reaches the nozzle it is thoroughly blend-
ed.
For materials that require more extensive blending,
the Noztek Pelletiser can be utilsed to cut the la-
ment in order to be reinserted back into the unit.
4. b LUBRICATION
The thrust bearing assembly will require occasional
lubrication; this is a relatively simple operation,
when the barrel is split remove the screw and
squirt a 2 second burst of a lubricant like WD40
Lithium
Grease around the outer diameter of the bearing.
For optimal performance we recommend that this
procedure is carried out every 20 hours of
operation.
4. c BARREL JAM
Depending on what type of material you are using,
you may experience a barrel jam. If at any time
during extrusion the motor starts to labour and
slow
right down then you should switch o the motor
immediately. In the rst instance you can raise the
temperature by 30c and turn on the motor. Failing
that, split the barrel and remove any debris.
4. d COOL DOWN
There are two fans connected to the main case:
One is to cool the motor, the other is to cool the
heat sink section underneath the hopper.
This has been installed to reduce any hopper neck
clumping when extruding at higher temperatures.