6059-C Nitrogen Plastic Welding System Quick Start Guide

Initial Setup

Step 1

Unbox cart and remove accessories from box. Find the hot air welder and airless welder tips and screw them into the heating elements.

Step 2

Install your shop's quick disconnect plug into the bottom inlet port of the cart's air manifold.

Step 3

A short whip hose may be attached at the front of the manifold (if desired) to power your die grinder and sander.

Step 4

Install nitrogen tank (argon or argon/CO2 may also be used). Install included safety chains around tank. Adjust height of top tank cradle if necessary.

Step 5

Screw the nitrogen regulator into the tank. Do NOT use teflon tape. Tighten securely.

Start-Up Procedure

Step 1

Connect clean, dry, oil-free shop air to the air inlet of the manifold. Supply pressure should be between 60-120 psi. (4.1 - 8.3 bar)

IMPORTANT NOTE:You must use CLEAN, DRY, OIL-FREE air for the hot air welder. Water and/or oil inside the heating element will drastically shorten its life span.

Step 2

Connect clean, dry, oil-free shop air to air inlet. Supply pressure should be set between 60-80 psi. (4.14-5.52 bar)

Step 3

Adjust fine flow control on the air (left) side so the flow meter reads 15 LPM. You should feel air coming from the torch.

Step 4

Adjust hot air temperature control to Level 1 to prevent any current flow to heating element.

Step 5

Plug in and turn on power strip. Turn hot air power switch on. Verify that the yellow light on the "air" side and the green "pressure safe" lights are glowing.

Step 6

To turn on the nitrogen, Turn the pressure screw counter-clockwise on the nitrogen tank regulator to prevent possible overpressure from damaging downstream components or the tank regulator.

Step 7

Open nitorgen tank valve slowly. Check that the tank gauge needle shows some pressure in the tank.

Step 8

Turn the screw clockwise until the outlet side gauge shows 15 psi (1 bar).

Step 9

Remove torch from the holster to switch to nitrogen. Adjust the pressure on the nitrogen (right) side so the fl ow meter reads 12 LPM. You should feel nitrogen gas coming from the torch.

Step 10

Switch the air selector switch back and forth between and nitrogen, making sure that the yellow lights indicate which side is flowing, that the green pressure safe light is glowing on both sides, and that you have flow from the torch on both sides. Leave on air at all times except when you are actually welding.

Step 11

Turn the temperature control dial to the proper level for the plastic you are working with. Let the welder warm up for five minutes before use.

CAUTION:You must ALWAYS maintain airflow through the welder while it is hot or the power is on. Failure to do so will burn out your heating element. Polyvance DOES NOT WARRANT the heating element because its life is completely under YOUR control.

Step 12

Do NOT leave on heat level 7 or 8 for any length of time because you will overheat the element! These setting are appropriate for higher airflow settings and thicker plastics, NOT for thin plastics like used for most automotive parts.

Step 13

Watch the instructional DVD to learn how to use the plastic welder. Practice on a scrap bumper first before you do any actual repairs. If you don't have the DVD, you can view the videos that are on the DVD from our YouTube playlist.

IMPORTANT:The shutdown procedure is VERY IMPORTANT for maxmizing the life of your heating element. You MUST shut down power to the unit first, then let clean, dry, oil-free air flow until the heating element is completely cool. YOU are in control of your heating element's life. Polyvance cannot warrant the heating elements for this reason.

Shutdown Procedure

Step 1

Place torch in the upper holster and turn the air temperature control to Level 1 to shut down the power to the heating element. Turn up the airflow to >25 LPM to speed the cooling process.

Step 2

Close the nitrogen tank valve. This will prevent any downstream leaks from draining the tank while the welder is off.

Step 3

Let the air flow for 10 minutes or until the air flowing from the welding tip is completely cold.

Step 4

Shut off main power and stop airflow by unscrewing the air regulator knob until loose. Disconnect air supply and unplug from the wall.

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