Walter SURFOX 304 User Manual

SURFOX 304

User’s guide

Manuel de l’utilisateur

Manual del usuario Manual do Usuário

SURFOX website

(Link to surfox.com)

Table of contents

1 Introduction 2 2 Safety instructions 3 3 Equipment controls 4

A) Control panel pictograms 4 B) Front and back view of the machine 5 C) Wand control buttons 6 D) Fume elimination system 6 E) Tip repositioning (comfort for operator) 6 4 Control panel 7 A) Main power switch 7 B) Wand and accessory selector knob 7 C) Current mode selector knob 7 D) Solution pump switch 7 E) Indicator lights 7 F) Accessory outlet 7 5 Start-up procedure 8 A) What is included in the box 8 B) Filling the reservoir 8 C) Connecting air supply 8 D) Plugging in the power cord 8 E) Plugging in the ground clamp 8

6 Using the large wand to electrochemically clean, polish and passivate 9

A) Selecting the proper wand and accessory 9 B) Selecting the proper current type, AC or DC and

proper current level, STD or MAX 9 C) Selecting the proper pumping mode 9 D) Cleaning and passivating 9 E) Neutralizing 9 7 Large wand accessories 10 A) Selection and mounting of the cleaning

pads and tips 10 B) PTFE clamp rings 12 C) SURFOX electrolyte solutions 12 D) Mounting a cleaning pad 12

8 Using the micro wand (optional) to clean, polish

and passivate 13

A) Selecting the proper wand and accessory 13 B) Selecting the proper current type, AC or DC and

proper curent level, STD or MAX 13 C) Manual pumping mode 13 D) Cleaning and passivating 13 E) Neutralizing 13 9 Using the marking/etching wand (optional) 14 A) Marking kits 14 B) Selecting the proper wand and accessory 14 C) Selecting the proper current type, AC or DC and

proper curent level, STD or MAX 14 10 Neutralizing 15 A) Directions for neutralizing SURFOX

electrolyte cleaning solutions 15 B) SURFOX weld cleaning and neutralization

procedure 15 11 Safety features 16 A) Sparks on the tip/work piece 16 B) Internal temperature 16 C) AC/DC current basics 16 D) AC/DC settings on the SURFOX machine 17 E) Welds that cannot be cleaned 17

12 Technical data 18 13 Warranty and service 18

A) Warranty policy 18 B) Repair and service 18

Version française 20 Versión española 39 Versão Português 58

SURFOX 304 User’s Guide 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 while completely passivating the stainless steel surface.

Our new generation of 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 completely as we take you step-by-step through the startup, operating and maintenance procedures of your new SURFOX built with extra durability to stand up to the heavy demands of industrial use. However, like any piece of electrical equipment, 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 other WALTER products, visit our website: www.walter.com

equipment. Your new SURFOX machine has been

weld cleaning equipment quickly,

owner’s manual

1.1 General Information

This manual provides all the information required for a safe installation, start-up and operation of the machine, along with troubleshooting and maintenance instructions.

WALTER is not liable for any consequences of incorrect use of its products, for example:

u Incorrect use of the machine or use by untrained

persons;

u Use in violation of the reference standards; u Incorrect installation; u Unsuitable main power supply; u Incorrect maintenance; u Incorrect maintenance;unauthorized modiﬁcations and

tampering;

u Incorrect maintenance;use of non-original spare parts

or spare parts not speciﬁed as suitable for the model in question;

u Incorrect maintenance;partial or total failure to follow the

instructions;

u Unexpected events; u And any other improper use.

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 current to clean welds. The process takes only a few seconds without damaging or scratching the surface of the parts to be cleaned.

The manual is an integral part of the machine and must be kept carefully with the machine until it is disposed of, to allow for reference to future updates. Should your copy of the manual be lost or unreadable, you can request a new copy from: WALTER - walter.com or surfox.com

The present manual reﬂects the condition of the machine at the time of manufacture and may not be deemed inadequate in case of updates due to subsequent experience.

WALTER reserves the right to update its products and manuals without prior notiﬁcation to users of previously manufactured machines.

Your SURFOX 304 machine can clean:

u TIG welds u Plasma welds u Laser welds u Spot welds u MIG welds

Basics of passivation:

u The cleaning of the welds is not only for aesthetic

purposes but most importantly for passivation.

u Passivation is the treatment of stainless steel surfaces

to remove contaminants and promote the formation of a thick and durable protective chromium oxyde layer.

u This passive layer will insure the corrosion resistance of

stainless steel.

u If passivation is not done properly, stainless steel and

heat affected zones may start to rust.

Safety instructions

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 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.

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 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 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 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 without its protective cover.

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 repaired

or replaced by a WALTER Authorized Service Center.

18. Do not use the unit if the switch does not turn ON/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 electrolyte weld cleaning

solutions contain 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 or SDS for complete safety data information on walter.com or surfox.com.

21. Use only WALTER SURFOX electrolyte solutions with

this unit and NEVER mix it with any other products.

22. The use of the fume elimation system (page 6.) is highly

recommended when working in conﬁded areas.

23. Do not use your SURFOX machine on the same struc-

ture when arc welding is in progress. Current could ground back tot he SURFOX machine and cause irreparable damage.

24. Store solution in its original container and in a safe place, out of the reach of children and other unquali ﬁed persons. Keep container contents clean. Do not reuse SURFOX electrolyte cleaning solutions.

25. 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.

26. 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 Authorized Service Center.

27.

When not in use, switch OFF and unplug the electrical cord and air hose (if connected). It must remain unplugged when replacing cleaning pads and accessories, while performing maintenance and before servicing.

28.

Store the unit in a dry safe place, out of the reach of

children and other unqualiﬁed persons.

SURFOX 304 User’s Guide 3

Safety instructions

Equipment controls

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 speciﬁed 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 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.

Equipment controls

A) Control panel pictograms

Outlet for micro-wand or marking wand

Indicator for wand tip power ON

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 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 (neutralized, rinsed and left off) and the tip 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 on walter.com or surfox.com.

Extension cord

Indicator for high internal temperature

Manual pumping mode Automatic pumping mode

Marking wand Micro-wand Large wand

MAX STD

STD MAX

Indicator for LOW solution level

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).

Current mode selector

Wand and Accessory Selector Knob

B) Front and back view of the machine

Equipment controls

ON/OFF button

Accessory outlet

Ground connector

Large wand hose (electrical and solution supply lines)

Control panel

SURFOX electrolyte solution ﬁlling and reservoir

Cleaning pad mounting unit

Compressed air connector (for fume elimination system)

Power cord

SURFOX 304 User’s Guide 5

Equipment controls

C) Large wand control buttons

The ON button is used to give power to the cleaning accessory. 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.

However, 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.

ON OFF

Cleaning Accessory

E) Tip repositioning (comfort for operator)

The tungsten tip may be rotated from the standard horizontal position to a vertical position or anywhere in between to make your cleaning as comfortable as possible. To loosen the right hand threaded fume elimination sleeve, turn tip to desired position and retighten sleeve.

Important: Always retighten fume elimination sleeve to ensure a good electrical connection and avoid damaging the contact points.

D) Fume elimination system (patented)

The SURFOX 304 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 large wand. The fume elimination system is turned OFF when the OFF button on the large wand is pressed. If 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 cleaning accessory. This preset regulated air pressure condenses the vapors out of the air.

Compressed air line ﬁtting

Cleaning accessory close up

Small openings

Control panel

A) Main power switch

Control panel

MAX STD

STD MAX

Turns the main power to the unit ON and OFF.

B) Wand and accessory selector

knob

Marking and etching wand. Select this

icon when using a marking/etching wand which has been plugged into the accessory outlet.

Micro wand. Select this icon when using the micro wand which has been plugged into the accessory outlet. Select the right accessory, either the tungsten insert, the brush or the large insert.

Large wand. Select this icon when using the large wand attached to the SURFOX unit.

C) Current mode selector

Selecting the proper current type, AC or DC, STD or MAX. AC for cleaning

and passivating the weld. DC for cleaning, passivating and polishing the weld. STD is recommended when using the tungsten inserts and pads, MAX is recommended when using the brush or the large graphite insert.

E) Indicator lights

Large wand power ON indicator. The

green light goes ON when the large wand ON button is pressed and there is power to the tip. Power to the tip is OFF when the large wand OFF button is pressed.

If the operating temperature is too high, the yellow light goes on and the machine will shut down and restart by itself when the temperature reaches an acceptable level.

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

D) Solution pump switch

Manual pumping mode. Choose the man-

ual pumping mode to control the amount of solution pumping to the tip. Hold the large 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 accessory's 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.

F) Accessory outlet

Outlet for optional micro wand or marking/etching wand. The marking/

etching wand is used to permanently etch/ mark your company name, logo, part number or other desired information onto stainless steel surfaces. The micro-wand is used to access hard to reach areas for cleaning and passivating, which are too small for the large wand.

SURFOX 304 User’s Guide 7

Start-up procedure

A) What is included in the box

u 1 x Large wand and connecting hose

u 1 x 48-R 136 Ground clamp

u 1 x 54-B 094 Wand Holder for Surfox 204/304

u Accessory kit containing:

• 1 x 54-B 095 Carbon Fiber Brush for Large Wand

• 1 x 54-B 099 Large Wand Brush Adaptor

• 1 x 54-B 101 Triangular Sleeve

• 1 x 54-B 102 Cylindrical Sleeve

• 1 x 48-R 133 Tungsten Insert (Already mounted on the large wand)

• 3 x 54-B 026 High Conductivity Standard Cleaning Pads

• 1 x 54-B 002 PTFE Clamping Ring

• 1 x 2.5 mm hexagonal key for changing tungsten insert

• 1 x 5.0 mm hexagonal key for mounting the wand holder

B) Filling the reservoir

Fill the reservoir in the back of the machine with SURFOX electrolyte solution. The reservoir holds 1.9 L of SURFOX electrolyte solution.

C) 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. (1000 KPa). If the air supply is not plugged into the machine, the machine will still work but there will not be any fume elimination.

D) Plugging in the power 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).

Reservoir

Ground clamp

Air supply connector

E) 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.

Using the large wand to electrochemically clean, polish and passivate

A) Selecting the proper wand and accessory

Tungsten insert

Brush

Large wand

Large graphite insert

B) Selecting the proper current type, AC or DC

and proper current level, STD or MAX

MAX STD

STD MAX

AC for cleaning and passivating the weld. DC for cleaning, passivating and polishing the weld.

STD is recommended when using the tungsten inserts and pads, MAX is recommended when using the brush or the large graphite insert.

WARNING! DC mode is used to polish the weld bead to match the mirror ﬁnish of the parent material.

TIP! When using the polishing mode (DC), use plenty

of SURFOX electrolyte solution.

Note: When using DC setting, the SURFOX electrolyte solution will become slightly yellow or will darken.

C) Selecting the proper pumping mode

Automatic mode

Manual mode

Manual pumping mode. Choose the manual pumping mode to control the amount of solution pumping to the tip. Hold the large 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.

D) Cleaning and passivating

To clean and passivate, press the large wand ON button. Make sure the cleaning accessory is saturated with SURFOX electrolyte cleaning solution before starting to work. If the cleaning accessory 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. Do not use the cleaning accessory like an abrasive pad.

WARNING! When using the machine for the ﬁrst time, there could be water in the system from factory testing. Adjust the liquid pump setting to automatic at maximum speed and let the liquid drip into a disposal cup for 2 minutes (amount of time required to empty the hose from the tank to the wand). Then, adjust the liquid pump setting back to desired pumping speed.

E) Neutralizing

1. Remove any excess of SURFOX electrolyte cleaning solution using a soft clean cloth.

2. Spray SURFOX-N on the surface.

3. Wipe dry with another soft clean cloth to avoid cross contamination.

Refer to neutralization procedure in neutralization section for instructions on how to properly neutralize (page 15).

SURFOX 304 User’s Guide 9

Large wand accessories

Large Wand Accessories

A) Selection and mounting of the cleaning pads and tips

Tungsten tips are made from high quality tungsten alloy material. Other materials will not resist the harsh environment created by the electrochemical process.

WARNING! When the insert is too worn, it can cause damage to the cleaning pads.

In this example of a worn insert, there are only two contact points. All the current comes out of these two points. Because of the lower available cross section, the temperature will be higher at the two points and the cleaning pads may become damaged or wear out prematurely.

O-Ring

Inserts

Tungsten insert 90° No: 48-R 133

Use with cleaning pads 54-B 026 or 54-B 040 and clamp ring 54-B 002 or boot 54-B 005

Tungsten insert 60° No: 54-B 016

Use with cleaning pad 54-B 027 and clamp ring 54-B 002 or boot 54-B 006

TIP! Resurface the insert using a bench grinding wheel

or angle grinder.

Note: Be sure to install the O-Ring located at the back of the insert whenever they are changed.

Tungsten insert kit for SURFOX 104, 204 and 304 Order No.: 54-B 012

Includes: 1 x 48-R 133 1 X 54-B 017 1 X 54-B 016 1 X 54-B 018

Narrow tungsten insert 90° No: 54-B 017

Use with cleaning pad 54-B 028 or 54-B 041 and clamp ring 54-B 020 or boot 54-B 007.

Large graphite insert for SURFOX 204 and 304 Order No.: 54-B 009

45 mm W - Ideal for surface renewing or restoring, and to clean the back of MIG welds

Carbon fiber brush for large wand on SURFOX 304 Order No.: 54-B 095

Without adaptor - Pack of 5

Triangular sleeve for large wand carbon fiber brush Order No.: 54-B 101

Narrow tungsten insert 60° No: 54-B 018

Use with cleaning pad 54-B 028 and clamp ring 54-B 020 or boot 54-B 008.

Large pads for large graphite insert Order No.: 54-B 043

90 mm L X 50 mm W X 2 mm H Pack of 10 with O-ring

Spare brush adaptor for large wand on SURFOX 304 Order No.: 54-B 099

Cylindrical sleeve for large wand carbon fiber brush Order No.: 54-B 102

Large pad for graphite insert for SURFOX 304 Order No.: 54-B 052

Pack of 5

Wand holder for SURFOX 304 and 204 Order No.: 54-B 094

Large wand accessories

High conductivity 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.

Cleaning pads are available in four types:

Standard cleaning pad No: 54-B 026

Use with insert 48-R 133

Inside corners cleaning pad No: 54-B 027

Use with insert 54-B 016

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)

Narrow cleaning pad No: 54-B 028

Use with inserts 54-B 017 and 54-B 018

Large cleaning pad No: 54-B 043

Use with large graphite insert 54-B 009

SURFOX 304 User’s Guide 11

Large wand accessories

B) 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 standard cleaning pads No: 54-B 002

Use with standard inserts. 10 per package.

C) SURFOX electrolyte solutions

Surfox electrolyte solutions are specially formulated phosphoric acid cleaning solutions designed to be used only in Walter SURFOX systems.

SURFOX-G

Electrolyte Cleaning Solution

Cleans up to 3-5 feet per minute.

1.5 L/50.7 oz. No: 54-A 065

STD Pack: 1 STD Carton: 4

5 L/1.3 gal. No: 54-A 066

1 STD Pack: 1 STD Carton: 1

20 L/5.2 gal. No: 54-A 067

STD Pack: 1 STD Carton: 1

208 L/55 gal. No: 54-A 068

STD Pack: 1 STD Carton: 1

D) Mounting a cleaning pad

1. Squeeze and insert clamp ring.

2. Insert cleaning pad.

3. Firmly press in tungsten tip.

SURFOX-T

Heavy-Duty

Cleans up to 3-5 feet per minute.

1.5 L/50.7 oz. No: 54-A 005

STD Pack: 1 STD Carton: 4

5 L/1.3 gal No: 54-A 006

1 STD Pack: 1 STD Carton: 1

20 L/5.2 gal. No: 54-A 007

STD Pack: 1 STD Carton: 1

208 L/55 gal. No: 54-A 008

STD Pack: 1 STD Carton: 1

Electrolyte Cleaning Solution

4. Remove tip with installed pad and clamp ring.

Note: When mounting classic pads, ensure the Ω sign is facing up on step 2.

Using the micro wand (optional) to clean and passivate

Using the micro-wand (optional) to clean, polish and passivate. 54-B 033 and 54-B 133

Use the micro-wand to get into tight places where the large wand cannot go. Plug the micro wand into the accessory outlet on the front panel.

A) Selecting the proper wand and accessory

Microwand

Brush

Tungsten insert

When this mode is selected, it automatically cuts the power to the large wand, stops the solution pump and the fume elimination system (if connected) from operating. Only power is provided to the micro wand/marking wand outlet. Be sure work piece is grounded.

Large graphite insert

B) Selecting the proper current type, AC or DC

and proper current level, STD or MAX

C) Manual pumping mode

The micro-wand uses a manual pumping mode only. One (1) press equals one (1) stroke. To pump more liquid, press repeatedly. See micro wand instructions for more information.

D) Cleaning and passivating

Screw in SURFOX electrolyte solution 100 ml tube onto the micro-wand. Make sure the cleaning pad is saturated with 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

1. Remove any excess of SURFOX electrolyte cleaning solution using a soft clean cloth.

MAX STD

STD MAX

AC for cleaning and passivating the weld. DC for cleaning, passivating and polishing the weld.

STD is recommended when using the tungsten inserts and pads, MAX is recommended when using the brush or the large graphite insert.

WARNING! DC mode is used to polish the weld bead to match the mirror ﬁnish of the parent material.

TIP! When using the polishing mode (DC), use plenty

of SURFOX electrolyte solution.

Note: When using DC setting, the SURFOX electrolyte solution will become slightly yellow or will darken.

2. Spray SURFOX-N on the surface.

3. Wipe dry with another soft clean cloth to avoid cross contamination.

Refer to neutralization procedure in neutralization section for instructions on how to properly neutralize.

SURFOX 304 User’s Guide 13

Using the marking/etching wand (optional)

A) Marking kits

Standard kit (54-B 080) includes:

• 1 marking/etching 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

B) Selecting the proper wand and accesssory

Turn the selector knob to the marking/etching wand icon.

Use the marking/etching wand to permanently mark or etch your company name, logo, part number or other desired information onto the surface of stainless steel, using permanent or disposable stencils. Plug the marking/etching wand into the accessory outlet on the front panel.

PRO kit (54-B 081) includes:

• 1 marking/etching 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

• 1 Stencil printer and software

• 1 Stencil paper roll 100 mm (W) X 20 m (L)

Marking/etching wand

C) Selecting the proper current type, AC or DC

and proper current level, STD or MAX

AC for marking using Surfox-M. DC for etching using Surfox-E.

STD current level is recommended for marking or etching.

MAX STD

STD MAX

TECHNICAL BULLETINS AVAILABLE ON OUR WEB SITE.

Neutralizing

The SURFOX-N liquid is a specially formulated 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.

A) Directions for neutralizing SURFOX electrolyte cleaning solutions

1. Remove any excess SURFOX electrolyte solution using a soft clean cloth.

2. Spray SURFOX-N on the surface.

3. Wipe dry with another soft clean cloth.

For more information about this product, refer to product MSDS or SDS on walter.com or surfox.com.

WARNING! Be sure to wipe off all excess SURFOX electrolyte solution from the surface and neutralize otherwise the inorganic salt from the phosphoric acid will adhere to the surface and cause deposits.

B) SURFOX weld cleaning and neutralization procedure

Clean the weld using the SURFOX machine and SURFOX electrolyte solutions. Work only 2 feet at a time.

Note: The cleaning pad 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.

After cleaning the weld with the SURFOX weld cleaning machine, the electrolyte solution must be neutralized.

1. Spray the affected area with SURFOX-N neutralizer. Allow to sit for 15 seconds on the surface.

2. 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.

Note: Failure to neutralize or neutralize properly will result in clouding, hazing and dulling of the surface.

SURFOX-N neutralizer Part No.

500 ml 54-A 023 5 L 54-A 026 20 L 54-A 027 208 L 54-A 028

Salt deposits due to unproper neutralization and rinsing.

SURFOX 304 User’s Guide 15

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 voltage every millisecond. If the voltage sharply increases creating a short, the system will automatically cut the power to the tip to avoid any damage to the equipment.

To restart the machine, simply press the large wand ON button.

WARNING! To avoid drawing too much amperage and automatically stopping the power to the tip, make sure that you touch only one surface at a time. The machine is set to work at a maximum of 30 amps. If the amperage goes above 30 amps, the machine automatically shuts down.

Example: On a ﬂat surface, the amperage is around 24 amps. The contact surface area is relatively small.

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 voltage, 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 voltage is continually changing between positive (+) and negative (-).

Example: An internal angle, which if you touch 2 sides simultaneously, the contact surface area is doubled, amperage goes above 30 amps and the machine stops.

Note: Automatic shut off if ground is not detected within 20 seconds.

Direct Current (DC) always ﬂows in the same direction, but it may increase and decrease. A DC voltage is always positive, but may increase and decrease.

Safety features

D) AC/DC settings on the SURFOX machine

Example of cleaning and passivation with SURFOX in AC mode:

Microscopic view of the material

BEFORE

Oxide layer to be removed

Example of cleaning and passivation with SURFOX in DC mode:

Microscopic view of the material

AFTER

Cleaning and passivation is

perfect. Cleans every crack in

the material.

E) Welds that cannot be cleaned

If the area around the weld is black (not blue) from contamination, this is a problem of high heat generated during the welding process. The contaminated areas do not conduct electricity. If there is no conductivity in the material, the SURFOX system cannot work.

If there are two welds on top of the other, the structure of the material has been seriously altered. These areas may not be cleaned.

The quality of the weld is critical. The better the weld, the easier it will be to clean.

Oxide layer to be removed

BEFORE

AFTER

Cleaning and passivation is

perfect. Cleans every crack in

the material.

Alteration of the material due to the DC setting

SURFOX 304 User’s Guide 17

Warranty and serviceTechnical data

1312

Technical data

MODEL: SURFOX 304

PART NUMBER: 54-D 314

INPUT VOLTAGE: 120 V, 50/60 Hz

OUTPUT VOLTAGE: 30 V, AC/DC

INPUT CURRENT: 7.5 Amps

OUTPUT CURRENT: 30 Amps Max, AC/DC

MAX. OUTPUT VOLTAGE: 33 V, AC/DC

DIMENSIONS: 525 mm x 370 mm x 250 mm

(20-2/3” x 9.84” x 14.57”)

RESERVOIR CAPACITY: 1.9 L

WEIGHT: 22 kg (48.5 lbs.)

INPUT AIR PRESSURE: 150 PSI max., 80 PSI min.

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 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, inciden- tal 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:

• Drain the SURFOX electrolyte solution from the reservoir

• 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

SURFOX 304 User’s Guide 19

Table des matières

1 Introduction 21 2 Directives de sécurité 22 3 Commandes de l’équipement 23

A) Pictogrammes du panneau de commande 23 B) Vue de l’appareil – avant et arrière 24 C) Boutons de contrôle de la baguette 25 D) Système d’élimination des fumées 25 E) Positionnement de la buse (confort de l’opérateur) 25 4 Panneau de commande 26 A) Interrupteur d’alimentation principal 26 B) Bouton de sélection de baguette et d'accessoires 26 C) Bouton de sélection du type de courant 26 D) Interrupteur de la pompe de solution 26 E) Témoins lumineux 26 F) Sortie pour les accessoires 26 5 Procédure de démarrage 27 A) Contenu de la boîte 27 B) Remplissage du réservoir 27 C) Raccordement de l’alimentation d’air 27 D) Branchement du cordon d’alimentation 27 E) Branchement du collier de mise à la terre 27

6 Utilisation de la baguette large pour le nettoyage, le polissage et la passivation électrochimique 28

A) Sélectionner la baguette et l'accessoire de

nettoyage 28

B) Choisir le bon type de courant AC ou DC et

la bonne intensité STD ou MAX 28 C) Sélectionner le mode de pompage adéquat 28 D) Nettoyage et passivation 28 E) Neutralisation 28 7 Accessoires pour baguette large 29 A) Sélection et assemblage des buses et tampons de

nettoyage 29 B) Bagues de serrage en PTFE 31 C) Solutions électrolytiques SURFOX 31

D) Assemblage d’un tampon nettoyeur 31

8 Utilisation de la micro-baguette pour le nettoyage,

le polissage et la passivation (facultatif) 32

A) Sélectionner la baguette et l'accessoire de

nettoyage 32

B) Choisir le bon type de courant AC ou DC et

la bonne intensité STD ou MAX 32 C) Mode de pompage manuel 32 D) Nettoyage et passivation 32 E) Neutralisation 32

9 Utilisation de la baguette de marquage/gravure (facultatif) 33

A) Trousses de marquage 33 B) Sélectionner la baguette et l'accessoire de

nettoyage 33 C) Choisir le bon type de courant AC ou DC et

la bonne intensité STD ou MAX 33 10 Neutralisation 34 A) Directives pour la neutralisation des solutions

de nettoyage électrolytiques SURFOX 34 B) Procédure de neutralisation et de nettoyage

des soudures SURFOX 34 11 Éléments de sécurité 35 A) Étincelles sur la buse ou la pièce de travail 35 B) Température interne 35 C) Rudiments du courant CA/CC 35 D) Réglages CA/CC pour l’appareil SURFOX 36 E) Les soudures qui ne peuvent pas être nettoyées 36

12 Données techniques 37 13 Garantie et service 37

A) Politique de garantie 37

B) Réparation et service 37

Introduction

Félicitations! Vous avez acheté le meilleur équipement de nettoyage de soudures et de passivation électrochimique sur le marché. L’équipement de nettoyage de soudures SURFOX la teinte de chaleur sur les zones affectées rapidement, facilement et de manière rentable, tout en permettant une passivation totale de la surface en acier inoxydable.

Notre nouvelle génération d’appareils SURFOX est équipée de panneaux convertisseurs à régulation automatique qui surveillent l’intensité du courant et le règlent automatiquement de manière optimale aﬁn d’assurer une efﬁcacité de nettoyage maximum sans perte de productivité.

Avant de commencer vos travaux, nous vous demandons de lire ce manuel du propriétaire SURFOX en entier; nous vous guiderons, étape par étape, du démarrage aux procédures de maintenance, en passant par la mise en œuvre de votre nouvel équipement SURFOX. Votre nouvel appareil SURFOX possède une durabilité accrue pour résister aux exigences élevées d’une utilisation industrielle. Toutefois, comme c’est le cas pour toute pièce d’équipement électrique, son utilisation exige des soins et la sécurité nécessaires à la protection de cet important investissement. En y apportant les soins et l’entretien appropriés, vous pourrez compter sur votre équipement SURFOX pendant des années.

fabriqué par WALTER permet de supprimer

u Alimentation principale inadéquate ;

u Mauvais entretien ;

u Modiﬁcations et manipulations non autorisées ;

u L'utilisation de pièces de rechange non originales ou des

pièces de rechange non spéciﬁées comme appropriées pour le modèle en question ;

u Respect partiel ou l'échec total du respecter des con-

signes ;

u Événements inattendus ;

u Et toute autre mauvaise utilisation de la machine.

Opérations

L’appareil SURFOX utilise un procédé électrochimique pour nettoyer et passiver les soudures faites sur l’acier inoxy dable. Les solutions électrolytiques utilisées par les appareils SURFOX sont à base d’acide phosphorique. Elles sont approuvées par l’industrie alimentaire et sont activées par un courant électrique pour nettoyer les soudures. Le traitement ne prend que quelques secondes et ne provoque aucun dommage ou égratignure à la surface des pièces nettoyées.

Pour obtenir des informations sur les autres produits

WALTER, visitez notre site Web : walter.com ou surfox.com

1.1 Informations générales

Ce manuel fournit toutes les informations nécessaires pour une installation sécuritaire, le démarrage et le fonctionnement de la machine, ainsi que des instructions de dépannage et de maintenance . Le manuel est une partie intégrante de la machine et doit être conservé avec la machine. Si votre copie du manuel est perdue ou illisible , vous pouvez demander une nouvelle copie à: WALTER - www. walter.com Le présent manuel reﬂète l'état de la machine au moment de la fabrication et ne peut être jugé insufﬁsant en cas de mises à jour en raison de d'expériences ultérieures . WALTER se réserve le droit de mettre à jour ses produits et ses manuels sans notiﬁcation préalable aux utilisateurs de machines fabriquées antérieurement . WALTER n'est pas responsable des conséquences d' une mauvaise utilisation de ses produits, par exemple :

u Mauvaise utilisation de la machine ou l'utilisation par des

personnes non qualiﬁées ;

u Utiliser en violation des normes de référence ;

u Installation incorrecte ;

Votre appareil SURFOX peut nettoyer :

u les soudures TIG; u les soudures plasma; u les soudures laser; u les soudures par points; u les soudures MIG

Rudiments de la passivation :

u Le nettoyage des soudures se fait non seulement à des

ﬁns esthétiques, mais surtout pour les besoins de passivation.

u La passivation est un traitement des surfaces en acier

inoxydable qui élimine les contaminants et favorise la formation d’une couche de protection en oxyde de chrome épaisse et durable.

u Cette « couche passive » permet une meilleure résistance

de l’acier inoxydable à la corrosion.

u Si la passivation n’est pas correctement réalisée, l’acier

inoxydable et les zones touchées par la chaleur peuvent commencer à rouiller.

SURFOX 304 Manuel de l’utilisateur 21

Directives de sécurité

Les appareils de nettoyage de soudure WALTER sont produits conformément aux normes en vigueur pour la fabrication, le rendement et la sécurité des produits industriels.

AVERTISSEMENT : Lorsque vous utilisez ces appareils, vous devez toujours prendre des précautions pour réduire les risques d’incendie, de décharges électriques et de blessures personnelles.

Avant d’utiliser cet appareil, lisez attentivement toutes les consignes de fonctionnement et de sécurité; assurez-vous de conserver ce manuel pour pouvoir vous y référer dans le futur.

1. Lisez ce manuel du propriétaire pour vous familiariser avec le fonctionnement de cet appareil, ses particularités, son champ d’application et ses limites.

2. Cet appareil est muni d’un cordon d’alimentation à 3 con ducteurs et de prises électriques enﬁchables doubles avec terre (3 ﬁches); il doit être branché à une prise adéquate avec mise à la terre.

3. Prévoyez un dégagement minimum de 8 pouces autour de l’appareil aﬁn de maintenir les ouvertures de ventilation libres de toute obstruction. Un débit d’air libre à travers les ouvertures de ventilation est nécessaire pour empêcher la surchauffe de l’appareil.

4. Gardez la zone de travail propre et bien éclairée. Un envi ronnement encombré peut provoquer des accidents. Enlevez tout matériel qui pourrait s’enﬂammer au contact d’étincelles. N’utilisez pas cet outil lorsque des liquides inﬂammables ou des gaz sont présents dans l’environnement. Gardez les poignées propres, sèches et sans souillure de solution nettoyante, d’huile ou de graisses. N’utilisez pas cet appareil sous la pluie et dans des endroits humides ou mouillés.

5. Gardez les enfants et les autres personnes à une distance sécuritaire des travaux. Veillez à ce que personne ne soit placé en dessous de vous lorsque vous travaillez en hauteur. Ne laissez personne sans formation adéquate utiliser cet appareil.

6. Portez toujours des vêtements appropriés et l’équipement de sécurité nécessaire lorsque vous travaillez, des gants de protection certiﬁés pour résister aux produits chimiques par exemple, des combinaisons ou chaussures de sécurité, etc.

7. Portez toujours des lunettes de protection approuvées.

8. Pendant le processus de nettoyage, la buse de la baguette et

la pièce de travail peuvent atteindre des températures extrême ment élevées; assurez-vous que ces pièces refroidissent avant de les mettre en contact avec une surface cutanée.

9. Évitez d’inhaler des fumées; n’utilisez l’appareil que dans un environnement bien ventilé. Utilisez un masque ﬁltrant au besoin.

10. Toute décharge électrique peut être dangereuse.

11. Si vous éprouvez des problèmes d’ordre électrique,

n’utilisez pas l’appareil avant qu’une personne qualiﬁée ait vériﬁé l’équipement.

12. N’utilisez jamais l’appareil lorsque le couvercle de protection est retiré.

13. Restez vigilant en tout temps lorsque vous utilisez cet appareil. Prenez garde à ce que vous faites. Utilisez votre bon sens. N’utilisez pas l’appareil lorsque vous êtes fatigué. Ne laissez jamais l’appareil en marche sans surveillance.

14. Assurez-vous que l’appareil est à l’arrêt (position OFF) avant de le brancher ou lors d’un déplacement aﬁn d’éviter un démarrage intempestif.

15. Tenez la baguette fermement. Ne travaillez pas à bout de bras

aﬁn de maintenir un bon équilibre en tout temps.

16. Avant l’utilisation, toutes les pièces devraient être examinées soigneusement pour vous assurer que l’appareil fonctionne correctement et remplisse sa fonction.

17. Les pièces endommagées ou défectueuses doivent être

réparées ou remplacées par un centre de service agréé par

WALTER.

18. N’utilisez pas l’appareil s’il est impossible de faire passer

l’interrupteur de l’arrêt à la mise en marche ou le contraire (ON et OFF).

19. N’utilisez que les accessoires recommandés pour ce système. Faites toujours une vériﬁcation des accessoires avant de com mencer le travail et ne les utilisez pas s’ils sont endommagés.

20. ATTENTION : Les solutions électrolytiques de nettoyage

SURFOX de WALTER contiennent de l’acide phosphorique pouvant causer des brûlures lorsqu’elles ne sont pas manipulées correctement. Évitez tout contact avec la peau.

Premiers soins : laver la zone affectée avec de l’eau. Contact avec les yeux : rincez à l’eau pendant 15 minutes

en soulevant les paupières de temps en temps. Appelez unmédecin au besoin. Ingestion : NE PAS PROVOQUER le vomissement. Rincez votre bouche, buvez beaucoup d’eau et recherchez une aide médicale. Reportez-vous aux ﬁches

signalétiques ou aux ﬁches de données de sécurité des produits WALTER pour obtenir des informations de sécurité exhaustives. Disonibles au walter.com ou surfox.com

21. N’utilisez que les solutions électrolytiques de nettoyage de soudures SURFOX de WALTER avec cet appareil; ne les mélangez JAMAIS avec d’autres solutions.

22. L'utilisation du système d'élimination des fumées (page 25)

est fortement recommandé lors de travaux dans des endroits conﬁnés.

23. N'utilisez pas votre machine SURFOX sur la même structure

lorsque vous soudez à l'arc. Le courant pourrait endomamger irréparablement motre machine SURFOX. pourrait terre retour tot il SURFOX machine et causer des dommages irréparables .

24. Entreposez la solution dans son contenant original et dans un endroit sûr se trouvant hors de portée des enfants et des personnes non qualiﬁées. Gardez le contenu du récipient propre. Ne réutilisez jamais les solutions électrolytiques de nettoyage SURFOX.

25. Ne touchez pas la buse de la baguette ou la pièce de travail lorsque vous utilisez l’appareil ou immédiatement après l’avoir utilisé; ils peuvent être extrêmement chauds et pourraient vous causer de graves brûlures.

26. Ne maltraitez pas le cordon d’alimentation. Ne tirez jamais cet

appareil en utilisant le cordon et ne tirez pas brusquement sur celui-ci pour débrancher l’appareil. Gardez le cordon électrique loin de la chaleur, de l’huile et des rebords tranchants. Inspectez régulièrement le cordon et, s’il est endommagé, faites-le remplacer par un centre de service agréé par

WALTER.

27. Lorsqu’il n’est pas utilisé, il faut mettre l’appareil en arrêt (OFF)

et débrancher le cordon électrique ainsi que le boyau pour l’air (s’il est branché). L’appareil doit également demeurer débran ché pour le remplacement de tampons de nettoyage ou d’autres accessoires ainsi que pendant les périodes d’entretien et de réparation.

28. Entreposez l’équipement dans un endroit sûr et sec se trouvant hors de portée des enfants et des personnes qui ne possèdent pas la formation appropriée.

+ 56 hidden pages

Walter SURFOX 304 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual