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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 dierent 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 airow through the welder while it is hot or the power is on.
Failure to do so will burn out your heang element. Polyvance DOES NOT WARRANT the
heang 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 signicant 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 airow 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
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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 airow is used. Extreme care must be taken to avoid overheating
the element.
