Walter MINI SURFOX User Manual

MINI SURFOX
User’s guide
Manuel de l’utilisateur
Manual de usuario
Manual do Usuário
SURFOX website
(Link to surfox.com)
Table of contents
Table of contents
1 Introduction 4
2 Safety Instructions 5
3 Equipment controls 6
Control panel pictograms 6
4 General Overview 8
5 Front view of the machine 8
6 Start-up procedures 9
A) Instructions 9 B) Mounting and cleaning pad 10
7 Neutralizing 10
Directions for neutralizing SURFOX electrolyte cleaning solutions 10
8 Accessories 11
A) Cleaning inserts and micro-wand kit 11 B) Electrolyte solutions 11 C) Cleaning pads 12 D) PTFE clamp rings 12 E) Carbon fiber brush and micro-wand kit 12 F) Large graphite insert 12
9 Marking kits and testing devices 13
A) Marking kits 13 B) SURFOX testing devices 13
10 Technical Data 14
11 Safety Features 14
A) Sparks on the tip/work piece 14 B) Internal temperature 14 C) AC/DC current basics 14
12 Warranty and service 15
A) Warranty policy 15 B) Repair and service 15
Version française 16 Versión española 31 Versão Português 45
Introduction
1
Introduction
Congratulations on purchasing the finest electrochemical weld cleaning and passivation equipment available today.
WALTER’s SURFOX
easily and cost effectively removes the heat tint from heat affected zones on stainless steel and aluminum while completely passivating the stainless steel surface.
SURFOX machines are equipped with self-regulating inverter boards, automatically monitoring and adjusting the current so as to ensure maximum cleaning effective­ness without loss of productivity.
Before starting, please read the SURFOX owner’s manual completely as we take you step-by-step through the start-up, operating and maintenance procedures of your new SURFOX equipment. Your new SURFOX machine has been built with extra durability to stand up to the heavy demands of industrial use. However, like any piece of electrical equip-ment, care and safety should always be taken when using and maintaining this valuable investment. With proper care and maintenance your SURFOX equip­ment will provide years of dependable service.
To learn more about the other WALTER products, visit our website: walter.com.
TM
weld cleaning equipment quickly,
Operation
The SURFOX machine works by an electrochemical process to clean and passivate welds on stainless steel. SURFOX electrolyte solutions are phosphoric acid based, approved for food industry, and are activated by an electrical cur-rent to clean welds. The process takes only a few seconds without damaging or scratching the surface of the parts to be cleaned.
Your SURFOX machine can clean:
TIG welds
Plasma welds
Laser welds
Spot welds
MIG welds (with Pulse technology)
Basics of passivation:
The cleaning of the welds is not only for aesthetic
purposes but most importantly for passivation.
Passivation is the treatment of stainless steel surfaces
to remove contaminants and promote the formation of a thick and durable protective chromium oxyde layer.
This passive layer will insure the corrosion resistance
of stainless steel.
If passivation is not done properly, stainless steel and
heat affected zones may start to rust.
4
Safety instructions
Safety instructions
2
WALTER weld cleaning machines are produced in accor-
dance with applicable standards governing the manufac­ture, performance and safety of industrial products.
WARNING: When using these machines, basic safety precautions should always be observed to reduce the risk of 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
through the vent openings is required to
prevent the unit from overheating.
Keep work area clean and well lit. A cluttered environ-
4. ment invites accidents. Remove any material that may be ignited by sparks. Do not use this tool when
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 chemical resistant gloves, overalls, 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 vapors, 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 avoid uninten­ tional 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.
18. Do not use the unit if the switch does not turn 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 electrolyte weld cleaning solution contains phosphoric acid and may cause burns when 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 product MSDS for complete
safety data information.
21. Use only WALTER SURFOX electrolyte weld cleaning solutions with this unit and NEVER mix it with any other products.
22. Store solutions in their original containers and in a safe place, out of the reach of children and other unquali-
persons. Keep container contents clean. Do not
reuse SURFOX electrolyte cleaning solutions.
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 re­ placed 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.
User’s Guide SURFOX MINI 5
Safety instructions
Equipment controls
2
Amperage
Before connecting this unit, check that the amperage shown on the rating plate is the same as the power supply.
Operating this unit on an amperage other than on its rating plate may result in personal injury to the user and damage the unit.
Preventive maintenance
After use, allow the tip to cool and remove the cleaning pad Neutralize with SURFOX-N and rinse the cleaning pad and wand tip with water and dry. Clean dust and dirt deposits from the exterior of the unit. Keep all 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
personnel only. Refer to Spare Parts List for the
ordering number.
vent openings
3
Equipment controls
Control panel pictograms
POWER
3
3
2
1
Cleaning
Marking
.
2
1
Polishing
Etching
INOX / STAINLESS
U
L
A
Application selectorPower selector
Ti
Transportation
Before transporting the machine, remove the electrolyte solution cartridge and make sure all connecting lines are 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 rough handling.
Storage
If the machine is to be stored for any length of time, the solution cartridge and cleaning pad must be removed (neutralized, rinsed and left off) and the insert neutralized, 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 of the SURFOX electrolyte cleaning solutions.
Extension cord
Outlet for micro-wand
or marking wand
Micro-wand selector
Marking wand selector
Outlet for ground connector
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).
6
General Overview
General Overview
4
SURFOX
electrolyte solution
100 ml cartridge
Micro-wand
ON/OFF
button
Ground cable
with clamp
Application
selector
Power
selector
SURFOX wand
power cable
User’s Guide SURFOX MINI 7
Front view of the machine
5
Front view of the machine
Power selector Application selector
ON/OFF button
Power cable connector for
cleaning wand and optional
marking wand
ELECTROCHEMICAL CLEANING: Select this setting when using the mini wand attached to the SURFOX unit. Select AC and 1, 2 or 3 depending on the amount of heat tint to remove and the type of material that is being cleaned.
ELECTROCHEMICAL POLISHING: This mode is used for cleaning, passivating and polishing the weld. The cleaning and passivating process takes longer in the DC mode than in the AC mode. DC mode is used to
polish the weld bead to match the surface of the finish.
Select DC and 1, 2 or 3. Stainless Steel only.
Ground connector
ELECTROCHEMICAL MARKING: Select this setting when using a marking/etching wand which has been plugged into the power cable connector. Select AC mode and 1, 2 or 3 for stainless steel, aluminum and titanium. Use SURFOX-M for Stainless Steel and Titanium; SURFOX-M ALU for Aluminum.
ELECTROCHEMICAL ETCHING: Select this setting when using a marking/etching wand which has been plugged into the power cable connector. Select DC mode and 1, 2 or 3. Stainless steel and Aluminum only. Use SURFOX-E.
8
Start-up procedure
Start-up procedure
6
A) Instructions
1. Place the unit on a flat stable surface, in a well
ventilated area where you will be working.
2. Connect ground cable to ground connector and attach grounding clamp to work piece.
3. Connect power cable to power connector.
4. Mount the insert and cleaning pad or the brush. SURFOX cleaning pads are made from highly heat resistant polymers for extra long service life. The cleaning pad must be replaced regularly.
Note: Never use the wand insert without a mounted cleaning pad. If the pad must be replaced while working, please observe the following:
• During the cleaning process, the wand tip and work
piece can reach very high temperatures.
Before replacing a worn cleaning pad or a brush, switch the unit OFF and disconnect from power supply, allow the wand tip to cool. The use of protective gloves is
recommended.
5. Screw on disposable SURFOX electrolyte solution cartridge to wand. Press the top of the wand with your
finger to pump solution to the pad.
6. With switch in the OFF position, connect the unit to a proper power supply as described under AMPERAGE.
7. Flip switch to the ON position.
8. Selecting the proper setting. Select low or high depending on the amount of heat tint to remove and the type of material that is being cleaned. Brush option and large insert can also be selected.
9. Make sure the cleaning pad or brush is saturated with SURFOX electrolyte solution before starting to work. If the cleaning pad or brush is too dry, it will wear prematurely. Start working when solution drips from the cleaning pad or brush.
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 and scrub. Doing this will shorten the life of the pad.
10. When done, place wand in holder and switch unit off.
User’s Guide SURFOX MINI 9
Start-up procedure
Neutralizing
6
B) Mounting and cleaning pad
Squeeze and insert clamp ring
7
Neutralizing
The SURFOX-N liquid is a specially formulated cleaner and neutralizer for the SURFOX electrolyte solutions. It is a powerful ready-to-use formula which leaves no residue, is non-toxic, solvent free, water-based and biodegradable.
Directions for cleaning and neutralizing SURFOX electrolyte cleaning solutions:
1. Remove any excess SURFOX-T electrolyte solution using a soft clean cloth. (This step is not required with SURFOX-G)
2. Spray SURFOX-N on the surface.
3. Wipe dry with a SURFOX POWERCLOTH.
For more information about this product, refer to product MSDS.
WARNING! When using SURFOX-T, be sure to wipe off all excess from the surface and clean/neutralize to prevent salt residues.
Insert cleaning pad
Press in wand tip
Clean the weld using the SURFOX machine and SURFOX electrolyte solutions. Work only 2 feet at a time.
Note: the cleaning pad/brush should be kept moist – not dripping.
1. After weld cleaning, use a clean cloth or paper towel and wipe the affected area in a squeegee action from left to right. Then discard the cloth or paper towel. (This step is not required when using SURFOX-G)
After cleaning the weld with the SURFOX weld cleaning machine, the electrolyte solution must be cleaned and neutralized.
1. Spray the affected area with SURFOX-N cleaner and neutralizer. Allow to sit for 15 seconds on the surface.
2. Use a SURFOX POWERCLOTH and wipe the affected area in a squeegee action from left to right.
Note: failure to neutralize or neutralize properly the SURFOX-T electrolyte solution will result in clouding, hazing and dulling of the surface.
Remove tip with installed pad
10
SURFOX-T electrolyte deposit due to unproper neutralization and rinsing.
SURFOX-N cleaner and neutralizer Part No.
500 ml 54-A 023 5 L 54-A 026 20 L 54-A 027 208 L 54-A 028
AccessoriesNeutralizing
87
Accessories
A) Cleaning inserts and micro-wand kit
They are made from high quality tungsten.
Cleaning inserts are available in several different shapes and sizes:
Tungsten insert 90° No: 54-B 036 Use with cleaning pad 54-B 026 or 54-B 027 and clamp ring 54-B 002. 10 per package.
Narrow tungsten insert 90° No: 54-B 038 Use with cleaning pad 54-B 028 and clamp ring 54-B 020. 10 per package. .
SURFOX POWERCLOTH Part No. 54-B 090
Replacement Micro-wand kit
No: 54-B 033
WARNING! When the insert is too worn, it can
cause damage to the cleaning pads.
B) Electrolyte solutions
SURFOX-T electrolyte cleaning solution
No: 54-A 001
100 ml cartridge, 6 per package.
Electrolyte straw
No: 48-R 294
10 per package.
SURFOX-G electrolyte cleaning solution
No: 54-A 061
100 ml cartridge, 6 per package.
User’s Guide SURFOX MINI 11
Accessories
8
C) Cleaning pads
Cleaning pads are made of a complex blend of highly conductive synthetic polymer which is very resistant to wear and which offers excellent thermal stability. For longer life, remove the cleaning pad and neutralize with SURFOX-N at the end of each working day.
Features
• Flexible: Can be folded many ways
• Soft on surfaces
• Can be used both sides
• Long lasting
• Highly conductive (4x more conductive than previous generation)
Cleaning pads are available in three sizes:
Standard cleaning pad No: 54-B 026
Dimensions: 46 mm L x 24 mm W x 4 mm T
USE WITH:
54-B 036
Inside corner cleaning pad No: 54-B 027
Dimensions: 60 mm L x 38 mm W x 2 mm T
USE WITH:
54-B 036
Narrow cleaning pad No: 54-B 028
Dimensions: 46 mm L x 24 mm W x 2 mm T
USE WITH:
54-B 038
D) PTFE clamp rings
PTFE clamp rings are designed to hold the cleaning pads on the tungsten inserts.
They are available in two sizes:
Narrow clamp ring for narrow pads
No: 54-B 020
Use with narrow inserts. 10 per package.
Clamp ring for cleaning pads
No: 54-B 002
Use with standard inserts. 10 per package.
E) Carbon Fiber brush and micro-wand kit
with carbon fiber brush
Carbon fiber brush
No: 54-B 157
To be mounted on Micro-wand 5 per package.
Micro-wand kit
No: 54-B 133
With carbon fiber brush for cleaning corners and intricate areas.
Spare Adaptor For mini-wand carbon
fiber brush
No: 54-B 150
F) Large graphite insert
No: 54-B 048
For small surface renewing and
cleaning the back of MIG welds. Use with inside corner cleaning pad.
No: 54-B 051
Pad for large graphite insert.
12
Marking kits and testing devices
A) Marking kits
Marking kits and testing devices
9
Standard kit No: 54-B 080
• 1 marking wand with graphite insert
• 35 mm X 10 mm and connecting cable
• 20 marking pads
• 5 O-Rings
• 1 SURFOX-M, 100 ml solution
• 1 SURFOX-E, 100 ml solution
The standard kit requires the use of permanent stencils.
* Also available, SURFOX-M 5 L to refill the squeeze
bottles. No: 54-A 036
B) SURFOX testing devices
PRO kit No: 54-B 081
• 1 marking wand with graphite insert
• 35 mm X 10 mm and connecting cable
• 20 marking pads
• 5 O-Rings
• 1 SURFOX-M, 100 ml solution
• 1 Stencil printer and software
• 1 Stencil paper roll 100 mm (W) X 20 m (L)
The PRO kit is offered with a stencil thermo printer for the printing of disposable stencils to permanently mark stainless steel surfaces. The printer comes with software that allows the creation of stencils for barcodes, serial numbers, lot and batch numbers, text, company logos, and more.
SURFOX Smart Passivation Tester (54-T 011)
To monitor the state of corrosion protection and to ensure proper passiv­ation of the workpiece.
Corrosion resistance of stainless steel is signifi­cantly reduced near welds as a result of the heating cycle. Visually, this can be seen as a darkened zone next to the weld. When electro-chemical cleaning is performed on the weld, corrosion risk is reduced but the treated zone still has to be passivated for 24-48 hours before the corrosion protection is fully restored.
Stainless steel grade Identification tester No: 54-T 001
There are countless types of stainless steels, mainly grouped in 3 categories or grades: 200, 300 and 400.
Since it is visually impossible to differentiate between 200, 304, 316 and 400 grade stainless steel, WALTER provides a test kit that allows customers to instantly identify the grade of stainless steel.
Product description
Testing device
Molybdenum reagent, 100 ml
Blotting paper
User’s Guide SURFOX MINI 13
Safety featuresTechnical data
1110
Technical data
MODEL: MINI SURFOX
PART NUMBER: 54–D 055
INPUT AMPERAGE: 120V, 50/60 Hz
OUTPUT AMPERAGE:
INPUT CURRENT: 4 Amps
OUTPUT CURRENT: MAX 15 Amps
10-30 V, AC/DC
Safety features
A) Sparks on the tip/work piece
To avoid short circuits (arcing), the machine automatically stops when the insert touches the work piece (metal to metal contact). There is an inverter board that monitors the amperage every millisecond. If the amperage sharply increases creating a short, the system will automatically cut the power to the tip to avoid any damage to the equipment.
B) Internal temperature
To protect the internal components of the machine, there are temperature sensors inside the machine. If the operat­ing temperature is too high, the machine will shut down and restart by itself when the temperature reaches an acceptable level. There is an internal fan inside the machine to keep all the components cool.
WARNING! The inside temperature can increase for
many reasons: high ambient temperature, lack of proper air circulation around the machine, fluctuations in amperage, electrical set-up in the shop, etc.
C) AC/DC current basics
Alternating Current (AC) flows one way, then the other way, continually reversing direction. An AC amperage is continually changing between positive (+) and negative (-).
Direct Current (DC) always flows in the same direction, but it may increase and decrease. A DC amperage is always positive, but may increase and decrease.
14
Warranty and service
12
Warranty and service
A) Warranty policy
All WALTER SURFOX cleaning systems and accessories are inspected and tested before shipment and are warranted to be free from any defect in material and faulty workmanship. Should any malfunction occur within six (6) months from the date of original purchase, return the complete system prepaid with proof of purchase, to the nearest WALTER Factory or Authorized Service Center. If an examination shows that the malfunction was caused by defective material or faulty workmanship, WALTER will repair (or at our option, replace the unit) without charge. This warranty does not apply when; normal maintenance is required, repairs or replacements have been made or were attempted by anyone other than WALTER authorized service personnel, and does not cover any damage caused by accidents, modifications, use of improper accessories, abuse or misuse, which also includes overloading the tool beyond its rated capacity as well as its continued use after partial failure. No other warranty, written or verbal, is authorized.
In no event shall WALTER be liable for any indirect, incidental or consequential damages from the sale of the product. This disclaimer applies both during and after the term of this warranty.
This warranty gives you specific rights. The provisions contained in this warranty are not intended to limit, modify, take away from, disclaim or exclude any warranties set forth in any Provincial or State legislation. To the extent required by law, the provisions in any Provincial, State or Federal legisla­tion with respect to warranties take precedence over the provisions in this warranty.
B) Repair and service
When shipping:
• Remove the SURFOX electrolyte solution cartridge from the wand and drain the wand
• Use original shipping case
• Use sufficient packing
• Ship on a small pallet
• Give detailed description of the problem as well as company name, address, phone and fax numbers and contact person.
User’s Guide SURFOX MINI 15
MINI SURFOX
Manuel de l’utilisateur
Table des matières
Table des matières
1 Introduction 18
2 Directives de sécurité 19
3 Panneau de commande 20
Pictogrammes 20
4 Aperçu général 21
5 Vue avant de l’appareil 22
6 Procédures de démarrage 23
A) Directives 23 B) Installation d’un tampon de nettoyage 24
7 Neutralisation 25
Directives pour la neutralisation des solutions 25 de nettoyage électrolytiques SURFOX
8 Accessoires 25
A) Embouts de nettoyage et trousse de rechange 25
pour micro baguette B) Solutions de nettoyage électrolytiques 25 C) Tampons de nettoyage 26 D) Bagues de serrage en PTFE 26 E) Brosse en fibre de carbone et trousse de micro baguette avec brosse en fibre de carbone 26 F) Embout large en graphite 26
9 Trousses de marquage et appareils de test 27
A) Trousse de marquage 27 B) Appareils de test SURFOX 27
10 Données techniques 28
11 Éléments de sécurité 28
A) Étincelles sur la buse ou la pièce de travail 28 B) Température interne 28 C) Rudiments du courant CA/CC 28
12 Garantie et service 29
A) Politique de garantie 29 B) Réparation et service 29
Manuel de l’utilisateur SURFOX MINI 17
Introduction
1
Introduction
Opérations
Félicitations pour l’achat de l’équipement de nettoyage et de passivation électrochimique de soudure le plus avancé techniquement sur le marché. L’équipement de nettoyage de soudures SURFOX facilement et économiquement la décoloration thermique des zones affectées par la chaleur sur l’acier inoxydable et l’aluminium tout en passivant complètement la surface en acier inoxydable.
Les machines SURFOX sont équipées de cartes inverseur auto-régulatrices qui surveillent et ajustent automatiquement
le courant afin d’assurer une efficacité de nettoyage
maximale sans perte de productivité.
Avant de commencer, veuillez lire complètement le manuel du propriétaire de SURFOX pour vous guider pas à pas dans le démarrage, l’exploitation et l’entretien de votre nouvel équipement SURFOX.
Votre nouvelle machine SURFOX a été construite avec une durabilité supérieure pour répondre aux exigences deman­dantes d’une utilisation industrielle. Cependant, comme toute pièce d’équipement électrique, il faut en prendre soin et s’assurer de son utilisation pour maintenir cet investisse­ment précieux. Avec des soins et une maintenance appropriés, votre équipement SURFOX offrira des années
de service fiable.
Pour en savoir plus sur les autres produits WALTER, visitez notre site web: walter.com
TM
de WALTER élimine rapidement,
La machine SURFOX fonctionne selon un procédé électrochimique pour nettoyer et passiver les soudures en acier inoxydable. Les solutions électrolytes SURFOX sont à base d’acide phosphorique, approuvées pour l’industrie alimentaire, et sont activées par un courant électrique pour nettoyer les soudures. Le processus ne prend que quelques secondes sans endommager ni égratigner la surface des pièces à nettoyer.
Votre machine SURFOX peut nettoyer :
Soudures TIG
Soudures plasma
Soudures au laser
Soudures par points
Soudures MIG (avec technologie pulsée)
Notions de passivation :
Le nettoyage des soudures n’est pas uniquement à
des fins esthétiques, mais surtout pour la passivation.
La passivation est le traitement des surfaces en acier
inoxydable pour éliminer les contaminants et favoriser la formation d’une couche d’oxyde de chrome de protection épaisse et durable.
Cette couche passive assure la résistance à la
corrosion de l’acier inoxydable.
18
Si la passivation n’est pas effectuée correctement,
l’acier inoxydable et les zones affectées par la chaleur peuvent commencer à rouiller
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