Polyvance 6049-C Nitro Fuzer Lite User manual

6049-C Nitro Fuzer Lite - 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. Assemble the welding cart and mount the
6049 welder to the top shelf using 2 sheet
metal screws (included). Connect the air
manifold to the air inlet on the back of the
welder with the green tubing.
2. Unpack the accessories box. Place
the welding rod in the bins on top of the
cart and thread the welding tips into the
appropriate welder.
3. Place the nitrogen welder into the top
holster and make sure there is nothing
ammable near the hot end of welder.
Place the airless welder into the lower
holster.
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 hose to the
front of the manifold to power air tools.
5. Secure your nitrogen tank to the back of
the cart with chains (included), move the top
tank cradle as needed. Mount the regulator
to the nitrogen bottle. Connect the N2inlet
on the welder to the regulator with tubing.
6. With the welder o󰀨, connect your
CLEAN, DRY, and OIL-FREE shop air
supply to the manifold.
Welder will not turn on.
• Check power supply to welder.
• Check wall outlet for 120V.
• Make sure power strip is on.
• Turn on the main power switch.
• Check that all cords going to the welder are plugged in.
• Check fuse on the back of the welder.
Fuse blows.
• Check heating elements for shorts. Remove the hot air element* and unplug the airless welder from the control panel. Check the resistance 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 elements check OK, turn the unit on with no elements installed. If the fuse continues to blow, contact Polyvance. If unit appears to function nor-
mally 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, its safe to assume the fault lies within the last element installed.
Nitrogen welder does not heat or is not hot enough.
• Turn the controller power “ON” by rotating the control knob clockwise.
• Check the airow, if the airow is too high, the air/N2 temperature will be low; turn up the heat or reduce the airow. If the airow is too low, the
green “safe” light will not illuminate and power will not be sent to the nitrogen welder. Turn up the airow until the green light illuminates. (If the
green light doesn’t turn on over 10 LPM, contact Polyvance.)
• If it still does not heat, check resistance of the heating element. (See above)
• If no faults are found, contact Polyvance.
Airless welder does not heat.
• Turn the controller power “ON” by rotating the control knob clockwise.
• Check the temperature setting. Low settings will produce very little heat.
• If still no heat, check resistance of the heating element (see above) or plug directly into a wall
outlet. If it does not get hot, the element is faulty; if it gets hot, the switch is faulty.
To shut o󰀨 individual welders:
Airless Welder:
Turn the airless welder control knob
counterclockwise until it clicks.
Nitrogen Welder:
Place welder into the top holster and
turn the nitrogen welder control knob
counterclockwise until it clicks
System Shut-down:
1. Shut o󰀨 main power on the back of the
welder
2. Close the valve on the nitrogen bottle,
but leave the compressed air connected
and on.
3. Allow the welder to completely cool
before disconnecting the air supply.
CAUTION: Always use
CLEAN, DRY, and OIL-FREE
air for the nitrogen welder.
Water and/or oil inside
the heating element will
drastically shorten its life
span.
Diagnostics:
Congratulations on purchasing one of the most versatile nitrogen plastic welders 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
your plastic welder. Scan the QR codes on the included 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. Additional videos are available to watch on our website at: http://www.polyvance.com/video
1128 Kirk Road, Rainsville, AL 35986
Tech Support: 800-633-3047
email: [email protected]
web: www.polyvance.com
1 2
3
Ah, cool
air!
REV: 11-2018
2A
3
4
Your hose
Your shop
tting
5A
Chain to
cart
Adjustable
tank cradle
6
Your shop air
5B
2B
1

Page 2 Page 3
1. Most bumper repairs can be done with the air/nitrogen ow set at 12 LPM,
but up to 15 LPM is commonly used. The chart above may be used as a
general guide for welding various materials. Using settings 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 airow, the heating element can be over-heated easily, 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 air and nitrogen ow. If an over-heat condition
continues uncorrected, the heating element will burn out and the handle may
be destroyed by the excessive heat becoming a potential re hazard.
2. To change from air to nitrogen, simply turn the selector valve to the desired
source. Be sure to switch back to the air setting when the weld is complete to
avoid using excess nitrogen.
3. Once the welder has warmed up, welding is accomplished by directing
the heated nitrogen at the intersection of the area to be repaired on the
base material and the welding rod. The welding rod should be applied
perpendicular to the base material with the welder aimed at approximately a
45° angle between the two.
4. The substrate should begin to gloss over in 3 to 5 seconds after applying
the heat. At this point, 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.
For more information on welding plastic, please watch the instructional videos
found at www.polyvance.com.
7. Adjust the nitrogen regulator on the
nitrogen bottle to read between 20 - 50 psi.
8. With the selector valve turned to AIR,
use the AIR ow valve on the front of the
welder to adjust the ow of air so the ow
gauge reads 12 LPM. At this setting, the
ball will oat halfway between the 10 and
15 LPM lines.
9. With the selector valve turned to N2,
use the N2 ow valve on the front of the
welder to adjust the ow of nitrogen so the
ow gauge reads 12 LPM.
10. Turn the selector valve back to AIR.
Always select AIR when the welder is idle
to conserve nitrogen!
11. On the back of the welder, turn on the
main power.
12. Check to make sure the green
“PRESSURE SAFE” light is on. The
welder will not heat if the “PRESSURE
SAFE” light is not on. If the light does
NOT illuminate when the airow is over 10
LPM, contact Polyvance tech support for
the adjustment procedure.
13. Turn on the nitrogen and airless
welders by rotating their respective control
knob clockwise. Start with the nitrogen
welder set about halfway up the dial, then
allow the welder to warm up for 5 to 10
minutes. If the welder is not hot enough to
weld, turn the welder up in incrementally
giving it time to preheat before increasing
the temperature further. Once a
satisfactory temperature is reached, it can
be simply turned to the same temperature
and airow setting immediately the next
time the welder is used.
14. After the welder has had a chance to
preheat, turn the selector valve to N2 to
begin welding. Be sure to turn the valve
back to AIR when the weld is complete.
Forgetting to turn the valve back to AIR will
consume a large amount of nitrogen and
will empty your nitrogen bottle in a short
amount of time.
Type of Plastic Melting Temp. Series of
Welding Rod
Approximate Temperature
Setting on Nitrogen Welder
Air Flow
LPM
Polyurethane (RIM, PUR) N.A. R01 7-10 (AIRLESS WELDER ONLY) N.A.
Polypropylene (PP) 160-166 °C (320 -331 °F) R02 7 12 - 15
ABS 105 (221°F) R03 6 12 - 15
Polyethylene (LDPE) 105-115 °C (221-239 °F) R04 7 12 - 15
TPO 177°C (350°F) R05 7 12 - 15
Nylon (PA) 269°C (516°F) R06 8 12 - 15
Polycarbonate (PC) 155°C (311°F) R07 7- 12 - 15
PVC 177°C (350°F) R09 7- 12 - 15
Polyethylene (HDPE) 190°C (375°F) R12 7+ 12 - 15
PET 254°C (490°F) R13 8- 12 - 15
ASA 220°C (428°F) R14 7+ 12 - 15
GTX 275-300°C (527-572°F) R15 8+ 12 - 15
Temperature Setting Suggestions*
* Most welding operations will be close to 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 overheat-
ing the element.
Welding Basics:
CAUTION: A LWAY S maintain adequate 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.
1
2
3
4
87
9a
12 LPM
11
Set between 20
and 50 psi
12 LPM
10
12 13a
14
9b
13b