Walter Surfox 203 User manual

User's Guide

60-C 783EFS

TABLE OF CONTENTS

Page

I - Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

II -

Safety instructions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4,5

III - Equipment controls

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

A) Control panel pictograms

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

B) Front and back view of the machine

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

C) Wand control buttons

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

D) Fume elimination system

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

IV - Control

panel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

A) Main power switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

B) Wand selector switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

C) Voltage regulating switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

D) Solution pump switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

E)

Indicator lights

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

F)

Accessory outlet

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

V - Start-up pro

cedure

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

A) What is included in the box

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

B) Filling the reservoir

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

C) Mounting a cleaning pad

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

D) Connecting

the air supply

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

E) Plugging in the power cord

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

F)

Plugging in the ground clamp

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

VI - Using the hand wan

d to clean and passivate

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

A) Selec

ting the proper mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

B) S

electing the proper

vo

ltage type

, AC or DC

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

C) S

electi

n

g the proper voltage setting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

D)

S

electing the proper pumpin

g mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

E)

Cleaning and passivating

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

F) Neutralizing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

VII - Using the Mini Wan

d (optional) to clean and passivate

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

A) Selecting the proper mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

5

B) Selecting the voltage type, AC or DC

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

C) Manual pumping mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

D) Cleaning and passivating

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

E) Neutralizing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

F) List of supplies and part numbers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

6

1

TABLE OF CONTENTS

Page

VIII - Using the Marking Wand (optional)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

7

,1

8

A) Selecting the proper mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

B) Selecting the voltage type, AC or DC

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

C) Selecting the proper voltage setting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

D) Procedure for marking

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17,18

E) Marking Wand supplies and part numbers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

IX - Neutralizing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

X - Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20,21

A) Cleaning tips

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

B) Cleaning pads

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

C) Cleaning boots

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

D) PTFE clamp rings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

E) Surfox-T solution

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

XI - Safety features

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

A) Sparks

on the tip/work piece

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

B) Interna

l temperature

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

C) AC/DC current basics

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

D) AC/DC settings on the Surfox machine

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

E) Welds that cannot be cleaned

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

XII - Technical data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

XIII - Wa

rranty and service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

A) War

ranty policy

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

B) Where to get service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

Version française

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xx

Versió española

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xx

2

TABLE OF CONTENTS

I

-

INTRODUCTION

Congratulations on purchasing the finest electrochemical weld cleaning and passivation equipment available today.

WALTER's SURFOX

TM

weld cleaning equipment quickly, easily and cost effectively removes the heat tint created

during TIG welding while completely passivating the stainless steel surface.

Be

fore starting

, please read the SURFOX

TM

owner's manual completely as we take you step-by-step through the

start-up, operating and ma

intenance procedures of your new SURFOX

TM

equipment. Your new SURFOX

TM

machine

has been built with extra d

urability to stand up to the hea

has been built with extra durability to stand up to the heahas been built with extra d

vy demands of industrial use. However, like any piece of

electrical equipment, care and safety shou

ld always be taken when using and ma

intaining this valuable investment.

With proper care and maintenance your SURFOX

TM

equipment will provide years of dependable service.

To learn more about the other Walter products

, visit our websites:

In Canada:

www.jwalter.ca

In USA:

www.jwalterinc.com

In Mexico:

mex.walter.com

OPERATION

The Surfox machine works by an electrochemical process to clean and passivate the welds on stainless steel.

Surfox-T is a phosphoric acid solution (approved for food industry) which is activated by an electrical current to

clean the welds. The process takes only a few seconds without damaging or scratching the surface of your part.

YOUR SURFOX

TM

MACHINE CAN CLEAN:

o TIG welds

o Plasma welds

o Laser welds

o Spot welds

o MIG welds (with Pulse technology)

BASICS OF PASSIVATION:

o Cleaning of the welds not only for aesthetic purposes but most importantly for passivation.

o Passivation is the treatment of stainless steel surfaces to remove contaminants and promote the

formation of the passive film layer.

o This passive film layer will assure the corrosion resistance of stainless steel.

o If passivation is not done properly, the stainless steel

and heat affected areas

may

start to rust.

3

I - INTRODUCTION

II - SAFETY INSTRUCTIONS

WALTER

weld cleaning machines are produced in accordance with applicable standards governing the

WALTER weld cleaning machines are produced in accordance with applicable standards governing the WALTER

manufacture, performance and safety of industrial products.

WARNING:

When using these machines, basic safety precautions should always be observed to reduce the risk

of fire, electrical shocks and personal injuries.

Before using this machine, read all Safety and Operating Instructions carefully and save this owner's

manual for future reference.

1. Read this owner's manual to familiarize yourself with this unit's operation, its particular features, applications

and limitations.

2. This unit is equipped with a 3-conductor power cord and 3-prong electrical plug, it must be connected to a

correspondingly grounded receptacle.

3. Allow a minimum of 8" clearance around the unit to keep all air openings clear of any obstruction. Free

airflow through the vent openings is required to prevent the unit from overheating.

4. Keep work area clean and well lit. A cluttered environment invites accidents. Remove any material that may be

ignited by sparks. Do not use this tool when flammable liquids or gases are present. Keep handles clean, dry

and free from cleaning solution, oil and grease. Do not use in rain, damp or wet locations.

5. Keep children and other persons at a safe distance from the work. Make sure no one is under you when

working in high places. Do not let unqualified persons handle this machine.

6. When working, always wear appropriate clothing and safety gear, such as suitable and safety approved

working gloves, ear plugs, safety shoes, etc.

7. Always wear approved safety goggles.

8. During the cleaning process, the wand tip and work piece can reach very high temperatures, allow to cool

before coming in contact with exposed skin.

9.

Avoid inhalation of fumes, use only in well ventilated areas. Use a respirator, if necessary.

10. All electric shocks can be potentially dangerous.

11. Should you encounter an electrical problem, do not use the unit until qualified personnel have inspected the

equipment.

12. Never operate the unit with its protective cover removed.

13. Stay alert at all times when handling this unit. Watch what you are doing. Use common sense. Do not operate

the tool when you are tired. Never leave it running unattended.

14. Make sure the switch is in its OFF position before plugging in or when moving the unit to a

void unintentional

starting.

15. Hold the wand firmly. Do not overreach, maintain good footing and balance at all times.

16. Before use, all parts should be carefully examined to determine that the unit will operate properly and

perform its intended function.

17. Parts that are damaged or defective should be properly repaired or replaced by a WALTER Factory Service

Center or a

WALTER

Authorized Service Center.

WALTER Authorized Service Center.WALTER

18. Do not use the unit if the switch does not turn it ON and OFF.

19. Use only the accessories recommended for this system. Always check accessories before starting to work and

do not use if damaged.

20.

CAUTION: WALTER

Surfox-T weld cleaning solution contains phosphoric acid and may cause burns when

CAUTION: WALTER Surfox-T weld cleaning solution contains phosphoric acid and may cause burns when CAUTION: WALTER

not handled properly. Avoid skin contact.

First aid:

Wash affected area with water.

Eye contact:

Flush with water for 15 minutes lifting eyelids occasionally. Contact physician if necessary.

Ingestion:

DO NOT induce vomiting. Rinse mouth, drink plenty of water and get medical attention.

Refer to WALTER MSDS #S-01E for complete safety data information.

21. Use only

WALTER

Surfox-T weld cleaning solution with this unit and NEVER mix it with any other products.

WALTER Surfox-T weld cleaning solution with this unit and NEVER mix it with any other products.WALTER

22. Store solution in its original container and in a safe place, out of the reach of children and other unqualified

persons. Keep container contents clean.

Do not

reuse Surfox-T solution.

4

II - SAFETY INSTRUCTIONS

5

23. Do not touch the wand tip or work piece while working or immediately after use, they may be extremely

hot and could cause serious burns.

24. Do not abuse the power cord. Never pull or lift this unit by its cord or yank to disconnect it from the

receptacle. Keep the cord away from heat, oil and sharp edges. Inspect the cord periodically, if damaged,

have it replaced by a WALTER Factory Service Center or a WALTER Authorized Service Center.

25. When not in use, switch OFF and unplug the electrical cord and air hose. It must also remain unplugged when

replacing cleaning pads and other accessories, while performing maintenance and before servicing.

26. Store the unit in a dry safe place, out of the reach of children and other unqualified persons.

VOLTAGE

Before connecting this unit, check that the voltage shown on the rating plate is the same as that of the power

source.

Operating this unit on a voltage other than specified on its rating plate may result in personal in

jury to the

Operating this unit on a voltage other than specified on its rating plate may result in personal injury to the Operating this unit on a voltage other than specified on its rating plate may result in personal in

user and

damage the unit.

PREVENTIVE MAINTENANCE

After use, allow the tip to cool and remove the cleaning pad. Rinse the cleaning pad and wand tip with water

and dry. Clean dust and dirt deposits from the exterior of the unit. Keep all airflow vent openings free of any

obstructions. Clean the power cord to prevent deterioration and check for possible damage to cord and plug.

Note:

Damaged cords must be replaced immediately by qualified personnel only. Refer to Spare Parts List for

the ordering number.

TRANSPORTATION

Before transporting the machine, make sure the cleaning solution reservoir and supply line are completely empty

and all connecting lines disconnected. The machine must be carefully packed in a suitable container and properly

protected.

WALTER

will not be held responsible for any damages resulting from leaked cleaning solution or

WALTER will not be held responsible for any damages resulting from leaked cleaning solution or WALTER

rough handling.

STORAGE

If the machine is to be stored for any length of time, the cleaning solution reservoir and supply line must be

emptied, cleaning pad removed (rinsed and left off) and the tip rinsed and dried. Store in a dry safe place to avoid

damage, especially to the electronic components.

WASTE DISPOSAL

Dispose of residual waste in compliance with Federal, Provincial, State and local environmental regulations.

Refer to WALTER Material Safety Data Sheet for Surfox-T #S-01E.

EXTENSION CORD

When an extension cord is needed, use wire size 14 (AWG) for up to 50 feet (15 meters) and size 12 (AWG) for 50

to 100 feet (15 to 30 meters).

II - SAFETY INSTRUCTIONS

A) CONTROL PANEL PICTOGRAMS

Outlet for Mini Wand or Marking Wand Indicator for unit power ON

Indicator for wand tip power ON Indicator for LOW solution level

Manual pumping mode Automatic pumping mode

Marking Wand selector Mini Wand selector

Cleaning Wand selector Voltage selector

III - EQUIPMENT CONTROLS

6

III - EQUIPMENT CONTROLS

7

Cleaning pad

mounting unit

Surfox-T filling and

reservoir

Wand holder

Compressed air

connector (for fume

elimination system)

ON/OFF button

Accessory outlet

Ground connector

Control panel

III -

EQUIPMENT CONTROLS

Power cord

Hand Wand hose

(electrical and

solution supply lines)

C) WAND CONTROL BUTTONS

The ON butt

on is used to give power to the Tungsten tip. When the pumping mode is set to manual,

press the

ON button to activate the pump.

Press and keep the button pressed to get continuous flow of liquid.

How

ever, if the pumping mode is set to automatic, press the ON button once to activate the pump. To stop the

pump, press the OFF button. When finished working with the machine (in either mode) make sure to press

the

OFF button.

Once the ON button is pressed, there will be continuous power at the tip until the OFF button is pressed.

D

) FUME ELIMINATION SYSTEM (PATENTED)

The

Surfox 203

machine comes with the integrated fume elimination system. This system provides for better

working conditions. Although the fumes are non-toxic and non hazardous, they can be uncomfortable when

working in confined areas.

To activate this feature simply connect a compressed air line (150 PSI max., 80 PSI min.) to the fitting at the

back of the machine. The fume elimination system is automatically activated when the ON button is pressed on

the Hand Wand. The fume elimination system is turned OFF when the OFF button on the Hand Wand is

pressed.

I

f the fume elimination system is not wanted, simply disconnect the compressed air line.

The working principle is quite simple and highly effective; the air comes out through the small openings behind

the Tungsten tip. This preset regulated air pressure condenses the vapors out of the air.

8

Tungsten tip

ON

OFF

III -

EQUIPMENT CONTROLS

Small openings

Compressed

air line fitting

IV - CONTROL PANEL

A

) MAIN POWER SWITCH

Turns the main power to the unit

ON

and

OFF

.

B) WAND SELECTOR SWITCH

Marking Wand selector.

Select this setting when using a Marking Wand which has been

plugged into the accessory outlet. Select AC for stainless steel and DC for aluminum.

Mini Wand selector.

Select this setting when using the Mini Wand which has been plugged into

the accessory outlet. Select AC for cleaning and DC for polishing.

Hand Wand se

lect

or

.

or.or

Select this setting when using the Hand Wand attached to the Surfox unit.

Select AC for cleaning and DC for polishing.

C) VOLTAGE REGULATOR SWITCH

Voltage selector.

Select a lower voltage for cleaning on delicate surfaces (mirror finish).

Select a higher voltage for thicker plates. The selector controls the voltage for all outlets (except

the Marking Wand which is preset at 12 Volts when the wand selector is positioned for the

Marking Wand (either AC or DC)).

9

IV -

CONTROL PANEL

F

B

C

E

D

A

D) SOLUTION PUMP SWITCH

Manual pumping mode.

Choose the manual pumping mode to control the amount of solution

pumping to the tip. Hold the Hand Wand ON button down to pump solution to the tip. Release

the ON button to stop the pumping cycle. Always use enough solution to keep the cleaning pad

wet. Too little solution will reduce the cleaning pad life.

Automatic pumping mode.

To start the automatic pumping mode, press the ON button on the

wand. Once it is activated, it will automatically pump the liquid. The quantity of liquid can be

selected from less to more. Pumping will continue in this mode until the OFF button is pressed.

E) INDICATOR LIGHTS

Power ON i

ndicator

.

ndicator. ndicator

Green light is on when the unit is plugged in and the main power switch is

turned on.

Hand Wand power

ON in

dicator.

The yellow light goes ON when the Hand Wand ON button

is pressed and there is power to the tip. Power to the tip is OFF when the Hand Wand OFF

button is pressed.

Low solution level i

ndicator.

When solution level is low, the red indicator light will go on.

F

) ACCESSORY OUTLET

Outlet for optional Mini Wand or Marking Wand.

The Marking Wand is used to permanently

etch your company name, logo, part number or other desired information onto any metal surface.

The Mini Wand is used to access hard to reach areas for cleaning and passivating, which are too

small for the Hand Wand.

10

IV -

CONTROL PANEL

V - START-UP P

ROCEDURE

A) WHAT IS INCLUDED IN THE BOX

1- Surf

ox ma

1- Surfox ma 1- Surf

chine

2- Hand Wand and connecting hose

3

- Ground clamp

4- Accessory kit contai

ning:

- 3 cleaning pads

- 1 PTFE clamping ring

- 1 cleaning boot

- 1 x 2.5mm hexagonal key for changing Tungsten cleaning tips

B) FILLING THE RESERVOIR:

Fill the reservoir in the back of the machine with Surfox-T solution. The reservoir holds 1.9L of Surfox-T

solution.

C) MOUNTING A CLEANING PAD

1

Squeeze and insert clamp ring.

Insert cleaning pad with symbol

facing up.

Firmly press-in Tungsten tip.

Remove tip with installed pad

and retaining ring.

1

2

3

4

Reservoir

V

-

V- V

START-UP PRO

CEDURE

D) CONNECTING AIR SUPPLY

Connect the air supply at the back of the machine. Note that the maximum allowed pressure is 150 PSI max.,

80 PSI min. (1000KPa). If the air supply is not plugged into the machine, the machine will still work but there

will not be any fume elimination.

E

) PLUGGING IN THE POWER CORD

When an ext

ension cord is needed, use w

ire size 14 (AWG) for up to 50 feet (1

5 meters) and size 12 (AWG)

for 50 to 100 feet (15 to 30 meters).

F) PLUGGING IN THE GROUND CLAMP

Plug the ground clamp at the

front of the unit. Attach the clamp to the work piece being cleaned. The cleaning

and passivating process will not work if the part is not properly grounded.

12

V

-

V- V

START-UP PROC

EDURE

START-UP PROCEDURESTART-UP PROC

Air supply connector

Ground clamp

VI - USING THE HAND WAND TO CLEAN AND PASSIVATE

A) SELECTING THE PROPER MODE

B) SELECTING THE PROPER VOLTAGE TYPE, AC or DC

AC

for cleaning and passivating the weld.

DC

for cleaning, passivating and polishing the weld. The cleaning and passivating process takes longer in the

DC mode than in the AC mode.

WARNING!

DC mode is used to polish the weld bead to match the surface of the finish.

TIP!

When using the polishing mode (DC), use plenty of Surfox-T solution.

C) SELECTING THE PROPER VOLTAGE SETTING

Recommended voltage settings:

AC mode for cleaning and passivating:

Use

h

ig

her voltage for mill finish parts or thick plates. When

working on delicate surfaces, mirror finish or very thin gauge, lower the voltage.

Example: Mill finish 14 gauge 26 volts

Polished finish 16 gauge 18 volts

Mirror finish 16 gauge 12 volts

WARNING!

If uncertain of the material type, start at a lower voltage and increase as necessary. If the

voltage is too high, it can alter the surface by leaving a white halo effect.

DC mode for cleaning, passivating and polishing:

Use h

igher voltage for mirror finish. When working on

mill finish parts, use a lower voltage.

Example: Mill finish 14 gauge 12 volts

Polished finish 16 gauge 18 volts

Mirror finish 16 gauge 28 volts

Note:

When using the DC setting,

the Surfox-T solution will become slightly yellow or darken.

Hand

W

and

WandW

13

VI - USING THE HAND WAND TO CLEAN AND PASSIVATE

D) SELECTING THE PROPER PUMPING MODE

Manual pumping mode.

Choose the manual pumping mode to control the amount of solution pumping to the

tip. Hold the Hand Wand ON button down to pump solution to the tip. Release the ON button to stop the

pumping cycle. Always use enough solution to keep the cleaning pad wet. Too little solution will reduce the

cleaning pad life.

Automatic pumping mode.

To start the automatic pumping mode, press the ON button on the wand. Once it is

activated, it will automatically pump the liquid. The quantity of liquid can be selected from less to more.

Note:

It is best to use the manual mode at first, until you become familiar with the

cleaning system.

E) CLEANING AND PASSIVATING

To clean an

d passivate, press the Hand Wand ON button. Make sure the cleaning pad is sat

urated with

d passivate, press the Hand Wand ON button. Make sure the cleaning pad is saturated withd passivate, press the Hand Wand ON button. Make sure the cleaning pad is sat

Surfox-T solution

before starting to work. If the cleaning pad is too dry, it will wear prematurely. Star

t

working when solution dr

ips from the c

leaning pad.

Do not press hard, let the electrochemical process do the work. Do not use the cleaning pad like an abrasive

pad.

WARNING!

W

hen using the machine for the first time there could be water in the system from factory

testing. Let 1 or 2 ounces drip into a disposal cup before cleaning.

F) NEUTRALIZING (refer to the Surfox-N section on

page 1

9

)

1- Remove any excess of Surfox-T so

lution using a soft clean cl

oth.

2- Spray Surfox

-N on the surface.

3- Wipe dry with anot

her soft c

lean cloth.

Manual mode

Automatic mode

1

4

VI - USING THE HAND WAND TO CLEAN AND PASSIVATE

VII - USING THE MINI WAND (OPTIONAL)

TO CLEAN AND PASSIVATE

Use the Mini Wand to get into tight places where the Hand Wand cannot go. Plug the Mini Wand into the

accessory outlet on the front panel.

A) SELECTING THE PROPER MODE AND VOLTAGE TYPE, AC or DC

When this mode is selected

, it autom

atically cuts the power to the Hand Wand, stops the solution pump and the

fume

elimination system (if

connected) from operating. Only power is provided to the Mini Wand/Marking

elimination system (if connected) from operating. Only power is provided to the Mini Wand/Marking elimination system (if

Wand outlet. Be sure work piece is grounded.

AC

for cleaning and passivating the weld.

DC

for cleaning

, passivating and po

lishing the weld. The cleaning and passivating process takes longer in

the

DC mode tha

n in the AC mode.

WARNING!

DC m

ode is used to po

lish the weld bead to match the surface of the finish.

TIP!

W

hen using

the polishing mode (DC), use plenty of Surfox-T solution.

B)

SELECTING THE PROPER VOLTAGE SETTING

Recommended voltage settings:

AC mode for cleaning and passivating:

Use

h

ig

her voltage for mill finish parts or thick plates. When

working on delicate surfaces, mirror finish or very thin gauge, lower the voltage.

Example: Mill finish 14 gauge 26 volts

Polished finish 16 gauge 18 volts

Mirror finish 16 gauge 12 volts

WARNING!

If uncertain of the material type, start at a lower voltage and increase as necessary. If the

voltage is too high, it can alter the surface by leaving a white halo effect.

DC mode for cleaning, passivating and polishing:

Use h

igher voltage for mirror finish. When working on

mill finish parts, use a lower voltage.

Example: Mill finish 14 gauge 12 volts

Polished finish 16 gauge 18 volts

Mirror finish 16 gauge 28 volts

Mini

W

and

Wand W

15

VII

-

VII- VII

USING THE MINI WAN

D (OPTIONAL) TO C

USING THE MINI WAND (OPTIONAL) TO CUSING THE MINI WAN

LEAN AND PASSIVATE

D (OPTIONAL) TO CLEAN AND PASSIVATED (OPTIONAL) TO C

C) MANUAL PUMPING MODE

The Mini Wand uses a manual pumping mode only. One (1) press equals one (1) pump. To pump more liquid,

press repeatedly. See Mini Wand instructions for more information.

D) CLEANING AND PASSIVATING

Screw in Surfox-T solution 100ml tube onto the Mini Wand. Make sure the cleaning pad is saturated with

Surfox-T solution before starting to work. If the cleaning pad is too dry, it will wear prematurely. Start

working when solution drips from the cleaning pad.

Do not press hard, let the electrochemical process do the work. The cleaning pad is a bridge between the

machine and the weld. Do not use the cleaning pad like an abrasive pad.

E) NEUTRALIZING (refer to the Surfox-N section on

page 1

9

):

1- Remove any excess Surfox-T solution using a soft clean cloth

2- Spray Surfox-N on the surface

3- Wipe dry with another soft clean cloth

F) LIST OF SUPPLIES AND PART NUMBERS

Mini Wand kit part no.: 54-B 033

The kit includes:

1 Mini Wand cleaning torch 48-R 285

1 stainless steel cleaning tip 54-B 021 10 per package

1 cleaning pad 54-B 001 10 per package

1 PTFE clamping ring 54-B 002 10 per package

1 cleaning boot 54-B 005 5 per package

1 narrow stainless steel cleaning tip 54-B 022 10 per package

1 narrow cleaning pad 54-B 023 10 per package

1 narrow PTFE clamping ring 54-B 020 10 per package

1 narrow cleaning boot 54-B 007 5 per package

1 black power cord 54-B 063

1 x 2.5mm hex key to change cleaning tips

Surfox-T 100ml 54-A 001

6 per package

16

VI

-

VI- VI

USING THE MINI WAN

D (OPTIONAL) TO C

USING THE MINI WAND (OPTIONAL) TO CUSING THE MINI WAN

LEAN AND PASSIVATE

D (OPTIONAL) TO CLEAN AND PASSIVATED (OPTIONAL) TO C

VIII - USING THE MARKING WAND (OPTIONAL)

Use the Marking Wand to permanently etch your company name, logo, part number or other desired information onto

the surface of stainless steel, aluminum, brass, copper or ste

el. Plug the Marking Wand into the accessory outlet on the

front panel.

A) SELECTING THE PROPER MODE

When this mode is s

elected, it automatically cu

ts the power to the Hand Wand, stops the solution pump and the fume

elimination system (if connected) from operating. Only power is provided to the Mini Wand/Marking Wand outlet.

Be sure the work piece is grounded.

B) SELECTING THE VOLTAGE TYPE, AC or

DC

AC

for ma

rking on stainless steel

DC

for marking

on aluminum

C) SELECTING THE PROPER VOLTAGE SETTING

The voltage is automatically fixed at 12V in AC or

DC mode. You do not need to set the voltage when selecting the

Marking Wand mode.

D) PROCEDURE FOR MARKING

1- Di

p the Marking Wand in Surfox

-M soluti

on

until the pad is satura

ted. Surfox-M is a different solution than

Surfox-T, which is used in the cleaning and passivating process. Surfox-M is part number 54-B 053.

2

- Place the stencil into position.

3- Ground the

work piece.

4- Rub the Marking Wand over the top of the stencil with a firm, but light pressure. You can also use a technique of

dabbing the Marking Wand on the stencil.

Marking

W

and

WandW

17

VIII

-

VIII- VIII

USING THE MARKING WAN

D (OPTIONAL)

USING THE MARKING WAND (OPTIONAL)USING THE MARKING WAN

5- Remove the stencil.

TIP!

For best results, always tape the stencil in place using masking tape before marking.

6- Neutralize the work piece with Surfox-N.

7- Neutralize the stencil with Surfox-N, rince well with water and dry. Store the stencil between 2 sheets of

cardboard and keep in a dry place.

E) MARKING WAND SUPPLIES AND PART NUMBERS

Marking kit part no.: 54-B 013

18

The kit includes:

1 Marking Wand with 2 O-rings 54-B 061

10 Mark

ing pads

54-B 062 10 per package

1

Surfox-M 350ml 54-B 053

1 black power cord 54-B 063

1 solution container 54-B 065

5 temporary stencils 54-B 064 100 per package

1 sample custom stencil

VIII

-

VIII- VIII

USING THE MARKING WAN

D (OPTIONAL)

USING THE MARKING WAND (OPTIONAL)USING THE MARKING WAN

IX - NEUTRALIZING

The

Surfox-N liquid is a specially formulated neutralizer for the Surfox-T sol

ution. It is a powerful ready-t

o-use

formula which leaves no residue, is non-toxic, solvent free, water-based and biodegradable.

Surfox-N

; part n

o.: 54-A 023 (500ml sprayer)

Directions for ne

utralizing Sur

fox-T cleaning solution:

1- Remove any excess Surfox-T solution using a soft clean cloth.

2- Spray Su

rfox-N on the surface.

3- Wipe dry with another

soft clean cloth.

For more information about this product, refer to MSDS S-03E.

WARNING!

Be sure to wipe off all excess Surfox-T from the surface and neutralize

otherwise the inorganic s

alt

from the phosphoric acid will adhere to the surface and cause deposits.

Surfox-T deposit

19

IX - NEUTRALIZING

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Walter Surfox 203 User manual

Walter Surfox 203 User manual

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