Polyvance 6080-CG User manual

6080-CG Nitro Fuzer Welding Cart - Quick Start Guide
Getting started:
The shutdown procedure is VERY IMPORTANT for
maximizing the life of your heang element. You MUST
maintain airow through the heang element unl it
is completely cool. You are in control of your heang
element’s life! Polyvance cannot warrant the heang
elements for this reason.
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Welder Shut-down Procedure:
1. Unpack the accessories box. Place
the welding rod boxes and accessories
into the bins on top of the welding cart.
2. Thread the welding tips into the
appropriate welder. The nitrogen welder
may already have the tip installed. If
so remove the tape securing the tip for
shipping.
3. Place the welders into the holster on
the right side of the welder. Be sure to
place the nitrogen welder into the upper
holster and make sure there is nothing
ammable near the welder exhaust.
4. Install your shop’s male air tting in the
bottom of the air manifold on the front of
the cart. If desired, you can install a whip
hose to the front of the manifold to power
air tools or a blower.
5. With the welder o󰀨, connect CLEAN,
DRY, and OIL-FREE shop air to the
manifold. (100-150 psi recommended.)
The nitrogen generator will immediately
begin to remove oxygen and carbon
dioxide from the air supply.
Welder will not turn on.
• Check wall outlet for 120V.
• Make sure power strip is on.
• Check circuit breaker on the back of the welder.
• Check that all cords going to the welder are plugged in.
• Check power cords for electrical continuity with an multimeter.
Circuit breaker trips.
• Check heating elements for shorts. Remove the hot air element and
unplug the airless welder from the control panel. Check the resis-
tance of the elements using an Ohm meter.
• Hot air welder: 26.0 ± 1.0 Ohm
• Airless welder: 53 ± 3.0 Ohms
• If out of range, or an open circuit is indicated, replace the faulty heating element.
• If the elements are within specication, turn the unit on with no elements installed. If circuit breaker continues to trip, contact Polyvance. If unit
appears to function normally without the elements installed, plug in the airless welder only and test. If unit continues to operate normally, shut
power o󰀨, then reinstall the hot air element and test. If unit trips circuit during either test, it’s safe to assume the fault lies within the last device
installed.
Nitrogen welder does not heat or is not hot enough.
• Turn the controller power “ON” by pushing the control knob once and make sure the power is not set too low. Must be on for the element to heat.
If the airow is at 12, set the temp to 52 as a starting point.
• Check air ow to the hot air welder. If the green “safe” light does not ash, power will not be sent to the heating element. Turn up airow until the
green light illuminates. It should illuminate at approximately 10 LPM, if it doesn’t, call Polyvance.
• If it still does not heat, check the heating element. (See above.)
Airless welder does not heat.
• Set the temp to 100. Low settings will produce very little heat.
• If still no heat, check the heating element. (See above.) Replace if out of specication.
LED display malfunction.
• If both displays malfunction, the main control board is at fault.
• If one display malfunctions, the display board is generally at fault.
CAUTION: Always use CLEAN,
DRY, and OIL-FREE air for
the nitrogen welder. Water
and/or oil inside the nitrogen
generator or heating element
will permanently damage the
membrane and heating element
Diagnostics:
1128 Kirk Road, Rainsville, AL 35986
Tech Support: 800-633-3047
email: [e-mail]
web: www.polyvance.com
12a
3
1a
23
4
5
Optional whip
hose location
Your shop
tting
Install tips
Your shop air
Ah, cool
air!
To shut o󰀨 individual welders:
Airless Welder:
Press the airless welder control knob one
time. “OFF” will show on the display indi-
cating power to airless welder is no longer
being supplied.
Nitrogen Welder:
Place welder into the top holster and press
the nitrogen welder control knob one time.
“OFF” will show on the display indicating
power to the nitrogen welder is no longer
being supplied. Allow the welder to com-
pletely cool before disconnecting the air
supply.
System Shut-down:
1. Shut o󰀨 main power
2. Allow the nitrogen welder to completely
cool.
3. Disconnect the shop air supply.
Congratulations on purchasing the easiest-to-use nitrogen plastic welder on the market. Prior to powering up
the welder, please read and follow the directions outlined in this booklet on the set-up and use of your plastic
welder. Scan the included QR codes sheet using your smart phone to see how to use the welder. Failure to
read and fully understand these instructions or failure to watch the instructional videos will potentially cause
damage to your welder, will increase your risk of injury, and may cause the welder to become a re hazard.
Videos are also accessible on our website at: http://www.polyvance.com/videos
Rev. 11/2018
1b
2b
CAUTION: Do not
exceed 150 psi
compressed air
supply or damage
to the nitrogen
membrane may
occur.

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1. Most bumper repair can be done using the factory pre-set temperature
settings with the air/nitrogen ow set at 12 LPM, however the chart above may
be used to aid in ne-tuning the nitrogen welder for use on di󰀨erent materials.
Going outside the range on the chart is generally not needed, unless you are
welding unusually thin or thick material or if the material you are welding has an
unusually high or low melting point. It’s important to note that when increasing
the temperature without increasing the nitrogen ow, the heating element can
be over-heated, causing a dramatic reduction in the life-span of the element.
Over-heating is indicated by a glowing outer steel torch barrel. If this happens,
immediately turn down the temperature and turn up the nitrogen ow. If an
over-heat condition continues uncorrected for any length of time, a re hazard
will result, the heating element will burn out, and the handle of the torch may be
destroyed by the excessive heat.
2. Once the welder has warmed up remove the torch from the holster.
3. Welding is accomplished by directing the heated nitrogen to the intersection
of the base material and the welding rod. Start by melting the tip of the welding
rod, then the surface of the substrate. The substrate should begin to gloss over
in 3 to 5 seconds after applying the heat. The welding rod should be applied
perpendicular to the base material with the welder aimed at approximately a 45°
angle between the two.
4. Once the base material glosses over, begin pressing the rod downward
onto the surface, rolling it towards the heat. Be sure the surface of the rod and
the surface of the substrate are both melted when pushing the two materials
together. If the base material or the welding rod surface melts faster than the
other, adjust the torch angle so both surfaces melt at the same rate.
For more information on welding plastic, please watch the instructional videos
on Polyvance’s website at www.polyvance.com.
Welding Basics:
CAUTION: ALWAYS maintain airow through the welder while it is hot or the power is on.
Failure to do so will burn out your heang element. Polyvance DOES NOT WARRANT the
heang element because its life is completely under YOUR control.
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12 LPM
6. Note the location of the three stage
air lter system behind the side door of
the generator cabinet. Check lters daily
for contamination. If any contamination
is present, correct the source of the
contamination and purge the lter bowls.
If the lters appear dirty, wet, or oily
replace the lter(s). Irreversible damage
will occur if dirt, water, oil, or oil vapors
reach the nitrogen membrane resulting
in a signicant and permanent loss of
nitrogen purity. Note: Filter styles may vary
in appearance from the picture. Stacked
lters may also be used, which look like a
single lter housing.
7. Turn on the welder with the main power
switch. Both nitrogen and airless welders
will show “OFF.” Do not turn the nitrogen
welder on until the nitrogen ow is set
correctly.
8. Using the regulator on the front of the
welder, adjust the ow of nitrogen so the
ow gauge reads 12 LPM. At this setting,
the ball on the ow gauge will oat halfway
between the 10 and 15 LPM lines. Note:
Nitrogen will ow even with the main power
o󰀨, as long as compressed air is connected
to the welder.
9. Turn on the nitrogen and airless welders
by pushing their respective control knob
once. The nitrogen welder is preset to 52
and the airless welder is preset to 100.
These temperature settings are a starting
point for most polypropylene welding with
the air ow set at 12 LPM. If desired,
the set-point can be changed by rotating
the dial and a new initial set-point can be
programmed into the controller by pressing and holding the control knob until the display ashes.
10. Check that the green “SAFE” light is ashing. If the “SAFE” light is not on and ashing, power is not going to the
heating element and the welder will not heat. If the green “SAFE” light does NOT illuminate when the airow is over 10
LPM, contact Polyvance tech support for the adjustment procedure.
11. With the green light ashing, allow the welders to warm up 5 minutes before using.
Note: The green “Safe” light ashes in direct relation to the power setting; the higher the heat setting, the longer the ash
duration, the lower the setting, the shorter the ash duration.
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9a
10
6a 6b
12 LPM
9b
11
Type of Plastic Melting Temp. Series of
Welding Rod
Recommended Temperature
Setting on Nitrogen Welder Air Flow
Polyurethane (RIM, PUR) N.A. R01 52-68 (AIRLESS WELDER ONLY) N.A.
Polypropylene (PP) 160-166 °C (320 -331 °F) R02 52-68 12
ABS 105 (221°F) R03 44-56 12
Polyethylene (LDPE) 105-115 °C (221-239 °F) R04 44-56 12
TPO 177°C (350°F) R05 52-64 12
Nylon (PA) 269°C (516°F) R06 60-68 12
Polycarbonate (PC) 155°C (311°F) R07 44-52 12
PVC 177°C (350°F) R09 44-52 12
Polyethylene (HDPE) 190°C (375°F) R12 56-64 12
PET 254°C (490°F) R13 56-64 12
ASA 220°C (428°F) R14 44-52 12
GTX 275-300°C (527-572°F) R15 60-68 12
Temperature Setting Suggestions*
* Most welding operations will be at the recommended settings. Welding outside the
recommended range may be needed if the plastic being welded is very thin or thick or
if a higher or lower airow is used. Extreme care must be taken to avoid overheating
the element.